Level 2 Procedures Manual

‘11

LEVEL 2 PROCEDURES MANUAL

13870 E. 11 MILE Rd WARREN, MI 48089

TABLE OF CONTENTS

HUMAN RESOURCES 1.0

TRAINING AND DEVELOPMENT 1.1

CORPORATE QUALITY AND DEVELOPMENT 2.0

PROPER GROUP INTERNATIONAL MEETINGS 2.1

INTERNAL QUALITY AUDIT 2.2

CONTINUOUS IMPROVEMENT 2.3

MANAGEMENT REVIEW MTG OF QUALITY SYSTEM 2.4

SALES PRESENTATIONS PROPOSALS AND SKETCHES

SALES AND PROGRAM MANAGEMENT 3.0

REQUEST FOR QUOTATION 3.1

NEW CUSTOMER APPROVAL 3.2

PROJECT APQP PLAN 3.3

RECEIPT OF PURCHASE ORDER 3.4

NEW PROJECT IDENTIFICATION SYSTEM 3.5

KICK OFF/PRE-KICK OFF PHASE 3.6

CONCEPT PHASE 3.7

MANUFACTURING PROCESS PHASE 3.8

CUSTOM PROPERTY 3.9

POST SAMPLING PHASE 3.10

POST SHIPMENT PHASE 3.11

PROTOTYPE KICK OFF 3.12

PROJECT SHEDULING MEETING 3.13

TIMELINES 3.14

CHANGE ORDERS 3.15

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© Proper Group International All Rights Reserved

CONTENTS Cont…

TOOLING FEASIBILITY STUDY 3.16

CUSTOMER SATISFACTION 3.17

CORRECTIVE ACTION REPORTING AND RESPONSE 3.18

8-DISCIPLINE PROBLEM SOLVING METHOD 3.19

ACTION PLANS 3.20

TRYOUT SCHEDULING/PRE-SAMPLING PHASE 3.21

TRYOUT MATERIAL HANDLING 3.22

TRYOUT INSTRUCTIONS 3.23

ENGINEERING CHANGE WORKSHEET 3.25

QUALITY 4.0

CONTROL OF MEASURING AND TEST EQUIPMENT 4.1

GENERAL TOOLING TOLERANCES AND SPECIFICATIONS 4.2

CONTROL OF MACHINE CONTROLLERS AND TEST EQUIPMENT 4.3

SHIPPING AND RECEIVING 5.0

SHIPPING AND RECEIVING CUSTOMER MOLDS,TOOLS,AND COMPONENTS 5.1

HANDLING AND STORAGE 5.2

MANUFACTURING 6.0

IN PROCESS VERIFICATION 6.1

INCOMING IN PROCESS COMPONENTS AND MATERIAL INSPECTION 6.2

ALL DEPARTMENTS 7.0

RECORD RETENTION AND CONTROL 7.1

DOCUMENT CONTROL 7.2

PURCHASING 8.0

PURCHASING GUIDELINES 8.1

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CONTENTS Cont….

VENDOR GUIDELINES 8.2

MOLD CONSTRUCTION OUTSOURCE 8.4

VENDOR CHARGE BACK 8.5

DATA MANAGEMENT 9.0

INCOMING DATA AND NAMING CONVENTION 9.1

MANUFACTURING RELEASE 9.2

DATA TRANSFER PROFILE 9.3

CAD DATA CONVERSION VERIFICATION 9.4

CONTROL PLAN-FMEA 10.0

MANUFACTURING CONTROL PLANS 10.1

DESIGN FMEA 10.2

PROCESS FMEA 10.3

FACILITIES MANAGEMENT 11.0

FACILITIES MAINTENANCE 11.1

PREVENTATIVE MAINTENANCE 11.2

MAINTENANCE REQUESTS 11.3

BUILDING MAINTENANCE 11.4

MOLD CERTIFICATION 12.0

MOLD CERTIFICATION AND ACCEPTANCE 12.1

MOLD INSPECTION FOR TRYOUT 12.2

MOLD TRYOUT OPEN ISSUES 12.3

MOLD PERFORMANCE 12.4

FINAL DIMENSION MOLD CERTIFICATION 12.5

MOLD INSPECTION FOR SHIPMENT 12.6

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CONTENTS Cont….

CUSTOMER ACCEPTANCE 12.7

RAPID PROTOTYPE 13.0

SLA/LOM INSPECTION 13.1

RAPID PROTOTYPE COMPONENT INSPECTION 13.2

ORGANIZATIONAL CHARTS 14.0

MANAGEMENT ORGANIZATIONAL CHART 14.1

PROPER TOOLING ORGANIZATIONAL CHART 14.2

PROPER POLYMERS- ANDERSON ORGANIZATIONAL CHART 14.5

PROPER TOOLING- ANDERSON ORGANIZATIONAL CHART 14.6

PLASTICS ORGANIZATIONAL CHART 14.7

ENGINEERING 15.0

PRELIMINARY MOLD DESIGN PHASE 15.1

FINAL MOLD DESIGN PHASE 15.2

DESIGN OUTSOURCING 15.3

MOLDFLOW ANALYSIS PHASE 15.4

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CONTACTS

GEOFF O’BRIEN (CEO) [email protected]

MARK RUSCH (CFO) [email protected]

TOM RUCZYNSKI (VP-POLYMERS DIVISION) [email protected]

JOE GRIPPE (VP OF SALES) [email protected]

JARED CZEREW( AUTHOR) [email protected]

WEBSITES

www.propergroupintl.com

www.propertooling.com

www.properpolymers.com

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mailto:[email protected]�





http://www.propergroupintl.com/�

http://www.propertooling.com/�

http://www.properpolymers.com/�

PROCEDURES MANUAL

HUMAN RESOURCES (Section 1)

1.1 Training & Development PURPOSE This training policy defines the provisions made within the company to ensure that all personnel are adequately trained for the tasks that they are required to undertake. SCOPE All associates employed at Proper Group International RESPONSIBILITY The human resources department is responsible for establishing and maintaining the appropriate training records. The department supervisors and managers are responsible for determining associate training needs and ensuring that only personnel who are suitably qualified perform tasks requiring acquired skill. PROCEDURE

All tasks within Proper Group International, which are adversely affected by the lack of

acquired skill, will be identified and made the subject of a job description that reflects the extent and evidence of skill required.

All associates will receive appropriate training before and during carrying out manufacturing

or testing operations. Training programs are devised to ensure complete familiarity with all requirements of the

process. Records will be maintained of training that is given and the completion of training will be

subject to review at the end of training. Periodic review of training requirements will be made to ensure that training remains

effective, and to identify the needs for retraining. Documents All records for training and performance review are stored in the associate’s personnel and/or human resource files.

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1.1 Training & Development

Orientation of New Associates When new associates start with the company, an orientation is given to inform them of the

procedures and policies of the company. The New Associate Orientation Form 1.1 is used as a guide during this orientation.

The human resource department is responsible for filling out the Training Log Form 1.1b

and logging the information on the Training Log.

Training Programs offered for Proper Tooling

Apprenticeships

Proper Tooling offers apprenticeship training for mold design and moldmakers. Guidelines have been established to maintain a high standard of quality in Proper Tooling’s

apprenticeship program and to develop the proper skills in those associates accepted in the program.

The manager in charge of the Apprenticeship program is responsible for filling out the

Training Log Form 1.1b with all class and training information for each apprentice. The manager in charge will then send the Training Log Form 1.1b to the human resource

department, who will then log in the information on the Training Log.

Training Programs offered for Proper Group International

Tuition Reimbursement

If an associate takes an outside course related to their current job function from an accredited educational institution, they must ask their manager for approval to be eligible for tuition reimbursement prior to taking the course.

The qualifications and reimbursement procedures are outlined in the associate handbook

that each new associate receives upon employment. The associate is responsible for filling out the Training Log Form 1.1n with all class and

training information. The human resource department is responsible for ensuring that each associate who turns in a tuition reimbursement form, has also turned in the Training Log Form 1.1b. The human resource department will then log in the information on the Training Log.

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PROCEDURES MANUAL



On The Job Training

On the job training is for all new associates and any associates changing to a new job function.

Assistance for training is readily available to any associate needing help in developing new

skills. The supervisors and managers are responsible for filling out the Training Log Form 1.1b

whenever an associate has on the job training. The supervisor / manager will then send the Training Log Form 1.1b to the human resource

department, who will then log in the information on the Training Log.

Job Related Seminars

Job related seminars that will improve the job skills of an associate are available at the request of the associate upon approval of their supervisor. Supervisors may also send associates to a job related seminar.

The associate is responsible for ensuring the Training Log Form 1.1b is filled out. When an

associate in their department is approved to attend a job related seminar, their supervisor will make sure the information is recorded on the Training Log Form 1.1b

The Training Log Form 1.1b to the human resource department, who will then log in the

information on the Training Log.

In House Training Sessions

When a number of associates will benefit from a job-related course, either someone employed by Proper or an outside instructor will conduct in house training.

Qualified instructors are also contracted for courses that will help associates in areas such

as motivational, team building, investing, etc. The associate organizing of the in house training session is responsible for filling out the

Training Log Form 1.1b. The associate will then send the Training Log Form 1.1b to the human resource department,

who will then log in the information on the Training Log.

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PROCEDURES MANUAL



Internal Company Cross Training

When an associate travels to another facility location to train another associate, it must be documented on the Training Log Form 1.1b.

The travel coordinator is responsible for including the Training Log Form 1.1.b with the

travel package if this section is checked off on the Request for Travel Arrangements Form 6.6.

The associate cross training another associate is responsible for filling out the Training Log

Form 1.1b and sending it to the human resource department upon completion. The human resource department will then log the information onto the Training Log.

Other Training

Any other training that an associate receives throughout the year must be recorded on the Training Log Form 1.1b and sent to the human resource department.

All associates are responsible for ensuring their individual training is recorded on this form

and forwarded to the human resource department. The associate organizing the in house training session is responsible for filling out the

Training Log Form 1.1b. The associate will then send the Training Log Form 1.1b to the human resource department,

who will then log in the information on the Training Log.

Training Log The human resource department is responsible for logging in all information on the

Training Log. The human resource department files the Training Log Form 1.1b in a master file.

Once the human resource department receives the Training Log Form 1.1b, the type of training will be evaluated.

Evaluation of Training

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1.1 Training & Development (Cont..) The human resource department will determine if a Training Evaluation Form 1.1a is

needed. Some examples of the type of training that will require this form to be filled out are seminars, outside training, etc.

The human resource department will send the appropriate associate the Training Evaluation

Form 1.1a to fill out. The associate will then fill out this form and return it to the human resource department for

review. Once the Training Evaluation Form 1.1a is received by the human resource department, a

thorough review and sign off is required from this department. Upon this review additional action may or may not be required. It is the responsibility of the human resource department to initiate, keep track of, maintain,

and file these Training Evaluation Forms 1.1a. The Training Evaluation Form 1.1a is attached to the Training Log Form 1.1b and filed in a

master file. Training Effectiveness & Review

The human resource department will summarize collected data to analyze that our goals for

training and its effectiveness are met.

Performance Reviews is one method used to track the effectiveness of training. Supervisors / managers receive an email from the human resources department on a

monthly basis informing them of which associates are due a performance review that month.

A chart tracking the percentage of reviews submitted on-time and percentage of reviews completed will be included in this email.

Associate Training hours are tracked to see if the company’s goals for training are being met. An Associate Training matrix is sent to the supervisors / managers on a quarterly basis.

These analyses are prepared for review during the Quarterly Management Meetings.

(Reference Procedure – Proper Group International Meetings Section 2.1)

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1.1 Training & Development RELATED DOCUMENTATION Form – New Associate Orientation Checklist 1.1 Form – Training Evaluation 1.1a Form – Training Log 1.1b Form – Request for Travel Arrangements 6.6 Procedure – Proper Group International Meetings Section 2.1 Procedure – Associate Travel & Expenditure Procedures Section 6.6 Procedure – Safety Section 11.5 Level 1 – Human Resources – General Section 6.2.1 Level 1 – Competence, Awareness and Training Section 6.2.2 Reference – Training Records of Associates

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PROCEDURES MANUAL

CORPORATE QUALITY AND DEVELOPMENT (Section 2) 2.1 Proper Group International Meetings PURPOSE To monitor and report on the performance of Proper Group International. SCOPE This procedure defines the scope for plant meetings, topic, objectives, intervals, and participants. RESPONSIBILITY Each meeting has a different manager / supervisor responsible for ensuring the meetings are held. PROCEDURE Reference the Proper Group International Meetings Form 2.1 for all details. REFERENCE Form – Proper Group International Meetings 2.1 Level 1 – Management Commitment Section 5.1 Level 1 – Planning – Quality Objectives Section 5.4.1 Level 1 – Internal Communication Section 5.5.3 Level 1 – Review Input Section 5.6.2 Level 1 – Management Review – General Section 5.6.1 Level 1 – Competence, Awareness and Training Section 6.2.2 Level 1 – Planning of Product Realization Section 7.1 Level 1 – Analysis of Data Section 8.4 Level 1 – Preventive Action Section 8.5.3

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CORPORATE QUALITY AND DEVELOPMENT (Section 2) 2.2 Internal Quality Audit PURPOSE To evaluate and verify whether quality activities and related results comply with the quality management system of Proper Group International. SCOPE All locations, departments and personnel of Proper Group International affected by the quality management system and internal audit requirements. RESPONSIBILITY It is the responsibility of the management representative to ensure that internal audits take place on a scheduled basis. PROCEDURE An internal audit schedule is established and is updated at least annually including all shifts. A member of the internal audit team performs audits. Audits are performed on all requirements at a minimum of twice a year. The Quality

Management Internal Audit Schedule Form 2.2a is used as the guideline for when the audits take place.

The auditors do not have any direct association or responsibility for the area they are

auditing. New policies or procedures are not audited for a minimum of four weeks after the signed

approval date to ensure their full implementation. Internal auditors are considered qualified after successfully completing one or more of the

following options: completing an internal or external training course in quality system auditing. perform at least three audits under the supervision of a qualified quality system auditor

or; have attained an RAB, AIAG, or other recognized quality system auditor or lead auditor

certification. ASQ Certified Quality Auditor (CQA) is also acceptable.

Issuing Dept. Officer

Established Revision Rev # Corporate Quality &

Development 09/05/00 03/06/09 006

Rev: Detailed information for CARs and planning internal audits.

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PROCEDURES MANUAL

CORPORATE QUALITY AND DEVELOPMENT (Section 2) 2.2 Internal Quality Audit The audit is performed only to gather information, the auditor may take no corrective action. The internal audit team meets at least twice a year to prepare for the internal audits. At this

time, the lead auditor distributes the scheduled audit assignments to each auditor. Each auditor must contact the department manager to schedule and perform the internal

audit. The auditor fills out the Internal Audit Review Report Form 2.2 during the audit. The report contains the following information. questions asked / objective evidence conformance or nonconformance auditors notes / suggestions / comments

Any department that contains confidential documents may not be audited in such a way that

exposes those documents. An auditor may only be shown how an operation is done. Under no circumstances are any

auditors allowed to operate machinery during an audit. The internal audit team meets throughout the audit days at scheduled intervals as deemed

necessary. During these meetings the team will share observations, redirect or refocus the audit based

on observations made during the audit, etc. Initial write-ups of observations and corrective action requests are completed.

After corrective action requests are issued, the Audit Report Form 2.2c is filled out which is a

summary of observations, corrective actions, and any suggestions for opportunities for improvement.

A closing meeting is then scheduled including the following personnel: Officers of the Company General Managers / Supervisors Management Representative

Reference Procedure – Management Review Meeting of the Quality System Section 2.4

The Audit Report Form 2.2c is presented at the meeting along with the Corrective Action Report Form 2.2b.

The following forms are also filled out where required: Document Control Audit Matrix Form 2.2e New Associate Training Audit Matrix Form 2.2f Calibration Audit Matrix 2.2g Corrective Action Audit Matrix 2.2h

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PROCEDURES MANUAL

CORPORATE QUALITY AND DEVELOPMENT (Section 2) 2.2 Internal Quality Audit

Corrective Action Request Form 2.2b or CAR Procedure Corrective Action Requests Form 2.2b can be issued from an internal audit, a customer

complaint or internally. (Reference Procedure – Corrective Action Reporting & Response Section 3.18)

When there is a Corrective Action Report Form 2.2b written, a CAR number is assigned. The CAR is sent to the management representative for review and number assignment.

The CAR is logged onto the CAR Log Form 2.2d.

Each CAR will have a “Reply Requested By” date.

The CAR is distributed to the person who was audited and their immediate supervisor.

The CARs are monitored by the CAR Log Form 2.2d by the management representative.

CAR replies are forwarded to the internal audit team member who issued the CAR and/or the management representative by the required due date.

If a CAR is not received by the due date, an internal audit team associate will follow up /

notify the person who was issued the CAR, check on the status and adjust the due date or elevate CAR to the next management level.

If the CAR was elevated to the next level of management the CAR must close within 7

business days or it will be given to the President.

CAR replies include Root Cause, Immediate Action Taken, Action Planned to Prevent Recurrence, and a Date for Full Compliance.

The Reply is reviewed by an internal audit team member to determine if the reply is

satisfactory. If it is, then the CAR is signed by the internal audit team member that the Reply is Satisfactory. If it is not, the CAR is sent back to the associate and their immediate supervisor to review for improvement. The due date will be adjusted to a new date which will be determined on the current state the CAR is in.

Once everything is approved, the CAR information is updated on the CAR Log Form 2.2d

with the date for full compliance.

After the date for full compliance is passed, an internal audit team member will revisit the area and review and confirm the issue is compliant. This will take place within 2 weeks of the due date.

If everything is satisfactory, the CAR is signed by the internal audit team member that Action

Taken was Satisfactory along with the date. Evidence of Compliance is also documented on the form.

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CORPORATE QUALITY AND DEVELOPMENT (Section 2)

2.2 Internal Quality Audit (continued)

All CARs are also recorded on the Corrective Action Calendar in Outlook to ensure follow-up does occur in a timely manner. This calendar is maintained by the corporate quality & development associate.

Audit Schedule & Preparation An internal audit schedule is established and is updated at least annually. This schedule is

documented on the Quality Management Internal Audit Schedule Form 2.2a.

Audits are performed per the schedule which is a minimum of twice a year.

When it is time for an audit, the management representative will complete the audit schedule with the internal audit team member assignments.

In addition to the processes audited, follow-up for corrective actions will be conducted which

will include: Corrective Action Requests Form 2.2b 8Ds Form 3.19 Non Conformances from Registrar Audits (Reference Open Issues NCs)

Document Control will also be reviewed during the internal audit. The Table of Contents is reviewed. The audit team member will go through the

Table of Contents and indicate which documents have not been revised within a year.

The procedure will be flagged to audit to ensure that it is still up-to-date. These are recorded on the Document Review Form 2.2i Reference Procedure – Document Control Section 7.2

All findings will be presented in the Management Review of the Quality System meeting.

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PROCEDURES MANUAL

CORPORATE QUALITY AND DEVELOPMENT (Section 2) 2.2 Internal Quality Audit RELATED DOCUMENTATION Form – Internal Audit Report 2.2 Form – Quality Management Internal Audit Schedule 2.2a Form – Corrective Action Request 2.2b Form – Audit Report 2.2c Form – CAR Log 2.2d Form – Document Control Audit Matrix 2.2e Form – New Associate Training Audit Matrix 2.2f Form – Calibration Audit Matrix 2.2g Form – Corrective Action Audit Matrix 2.2h Form – Document Review 2.2i Procedure – Management Review Meeting of the Quality System Section 2.4 Procedure – Corrective Action Reporting & Response Section 3.18 Procedure – Document Control Section 7.2 Level 1 – Customer Satisfaction 8.2.1 Level 1 – Internal Audit Section 8.2.2 Level 1 – Correction Action Section 8.5.2 Reference – Corrective Action Calendar

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CORPORATE QUALITY AND DEVELOPMENT (Section 2) 2.3 Continuous Improvement PURPOSE Continuous improvement is a brainstorming activity for Proper Group International. Continuous improvements are made in all areas of the company from administrative through the manufacturing process to improve quality, timing, cost and customer satisfaction. SCOPE This applies to all areas of Proper Group International. RESPONSIBILITY The president has the overall responsibility for reviewing the continuous improvement ideas. The design lab is responsible for maintaining continuous improvement ideas. PROCEDURE Any associate may submit a Continuous Improvement Idea to their immediate supervisor. The president will review the Continuous Improvement Idea Form 2.3 for approval to go to

Phase 2 Investigation.

Continuous improvement ideas are documented on the Continuous Improvement Idea Form 2.3 including those that are not incorporated.

Not all continuous improvement ideas are implemented or prove successful. Some continuous improvement ideas that are implemented may require statistical

techniques to monitor progress and stability. All Continuous Improvement Idea Forms 2.3 are maintained in the Continuous Improvement

Manual located in the design lab.

A Continuous Improvement Idea Log Form 2.3a is kept listing all continuous improvement ideas and target dates for completion. This Continuous Improvement Idea Log Form 2.3a is reviewed at the quarterly management meeting.

Longer term projects are also listed on the Continuous Improvement Management Meeting

Open Issues Form 3.6c.



Development 01/01/01 02/01/09 003

Rev: longer term projects are listed in the mgt mtg open issues and reviewed in the qrtly mtg, design lab is responsible for CII

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PROCEDURES MANUAL

CORPORATE QUALITY AND DEVELOPMENT (Section 2) 2.3 Continuous Improvement (continued) The design lab manager is responsible for constant processing of Continuous Improvement

Ideas and completed tasks.

RELATED DOCUMENTATION Form – Continuous Improvement 2.3 Form – Continuous Improvement Idea Log 2.3a Form – Open Issues 3.6c Level 1 – General Section 8.1 Level 1 – Continual Improvement Section 8.5.1

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2.4 Management Review Meeting of the Quality System PURPOSE To monitor and report on the performance of Proper Group International’s Quality Management System. SCOPE The review process covers all applicable AS 9100 Quality System elements affecting Proper Group International. RESPONSIBILITY The management representative is responsible for gathering all referenced related documents and conducting a review of these items and any other pertinent information. The lead auditors are responsible for scheduling and conducting a review of the internal audits that have been completed. PROCEDURE Officers of the Company, general managers, department managers, lead auditors, and the

management representative attend this meeting. The minutes of these meetings are documented in the Management Meeting Review

Minutes Form 2.4 and filed in the corporate development department along with the internal audit results. They are also saved electronically.

A documented management review of Proper’s Quality Management System and internal

audit results is conducted and reported on after the regularly scheduled internal audits (twice a year) by Proper’s management.

All applicable processes of the quality management system are addressed during the

review. Other items reviewed, but not limited to, are: Audit Schedule Status of Preventive Action & Corrective Action Corrective Action Requests 8Ds Non Conformances from Registrar Audit (yearly) Customer Survey Results Vendor Survey Results Opportunities for Improvement Procedure / Process Review Open Issues

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2.4 Management Review Meeting of the Quality System RELATED DOCUMENTATION Form – Management Review Minutes 2.4 Form – Corrective Action Request 2.2b Form – Audit Report 2.2c Form – Customer Survey Summary 3.17a Form – 8D Matrix 3.19a Form – Non Conforming Production 6.2 Form – Supplier Questionnaire Review 8.2a Form – Mold Performance Evaluation Summary 12.4b Procedure – Internal Quality Audit Section 2.2 Level 1 – Internal Communication Section 5.5.3 Level 1 – Management Review – General Section 5.6.1 Level 1 – Review Input Section 5.6.2 Level 1 – Review Output Section 5.6.3 Level 1 – Internal Audit Section 8.2.2 Level 1 – Monitoring and Measurement of Processes Section 8.2.3 Level 1 – Preventive Action Section 8.5.3 Reference – Proper’s Quality Management System Policies and Procedures Reference – Proper’s Quality Policy & Objectives

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CORPORATE QUALITY AND DEVELOPMENT (Section 2) 2.5 Sales Presentations / Proposals, and Sketches / Screen Dumps Sales Presentations / Proposals If a formal written presentation is prepared as part of a proposal, the following language must appear prominently in the proposal:

The enclosed confidential and proprietary information is to be used for the sole purpose of enabling Proper Group International to develop a proposal for the (insert name of program). Reproduction or distribution of the confidential and proprietary information without the express written consent of Proper Group International is prohibited.

Sketches / Screen Dumps If there are any screen dumps of sketches or work that the Proper has done is the property of Proper, please make sure the following appears somewhere on each

page of each sketch submitted:



Development 03/01/03 01/19/09 002

Rev: Changed company name and logo

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PROCEDURES MANUAL

SALES AND PROGRAM MANAGEMENT (SECTION 3) 3.1 Request For Quotation PURPOSE This is a guideline for documenting incoming requests for quotations. SCOPE This procedure applies to Proper Tooling. RESPONSIBILITY It is the responsibility of the account manager for adherence to this procedure. The estimating administrative associate also has the responsibility of ensuring this request is filled out. PROCEDURE When a request for quotation is received from a customer, the account manager will review

all available information to determine whether a quotation can be processed.

If for any reason the quotation will not be processed, the account manager will contact the customer in writing to inform them of the reason that the quotation will not be processed.

A copy of this notice along with the original information received from the customer is

forwarded to the estimating administrative associate to be logged in as “No Quote” and filed.

If the quotation will be processed, the quotation package is assembled by the account manager. This will include all information received from the customer.

If part data is received from the customer to use for the quotation, a Data Request Form 9.1

is completed by the account manager and forwarded to data management.

A Request For Quotation Form 3.1 is then filled out and attached to the quotation package. All known information must be filled out on the form to aid in the quoting of the package. The quotation package is then forwarded to the estimating administrative associate to be

logged in and reviewed for completeness. The project costing associate then receives package and completes the quoting process.

If the package can be quoted, a formal quote is issued to the customer.


Established Revision Rev # Sales / Program

Management 09/05/00 03/06/09 003

Rev: Updated with detailed information on the quoting process including incomplete information

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PROCEDURES MANUAL

SALES AND PROGRAM MANAGEMENT (SECTION 3) 3.1 Request For Quotation (continued) If for any reason the quotation cannot be completed in the estimating department, the

account manager will be notified.

The account manager will contact the customer in writing to notify them that the quotation cannot be processed or to obtain the required information to allow the quotation process to be completed.

If the required information to complete the quotation is not received, a copy of the notice to

the customer will be filed with the quote package and the quote will be logged in as “No Quote” status.

RELATED DOCUMENTATION Form – Request For Quotation 3.1 Level 1 – Planning of Product Realization Section 7.1

3.1 Request For Quotation (continued) If for any reason the quotation cannot be completed in the estimating department, the

account manager will be notified.

The account manager will contact the customer in writing to notify them that the quotation cannot be processed or to obtain the required information to allow the quotation process to be completed.

If the required information to complete the quotation is not received, a copy of the notice to

the customer will be filed with the quote package and the quote will be logged in as “No Quote” status.

RELATED DOCUMENTATION Form – Request For Quotation 3.1 Level 1 – Planning of Product Realization Section 7.1

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PROCEDURES MANUAL

SALES AND PROGRAM MANAGEMENT (SECTION 3) 3.2 New Customer Approval PURPOSE To establish a procedure for approving and adding new customers into Proper Group International’s system. SCOPE This procedure applies to all new customers. RESPONSIBILITY It is the responsibility of the credit administrator to adhere to these guidelines. PROCEDURE In order to add a new customer to the approved customer list, the following forms must be

completed by the associate requesting a new customer: New Customer Approval Form 3.2 Proper Credit Application Form 3.2a If the credit limit is over $10,000, a D & B Report must be attached to the Credit

Application. The New Customer Approval Form 3.2 and the Proper Group International’s Credit

Application Form 3.2a must then be approved and signed by an Officer of the Company. All of the required forms are then forwarded to the credit administrator who is responsible for

inputting the customer. The credit administrator enters in the new customer and assigns the customer a number. Customer Credit Limit After a customer is put into our system and has a customer number, the amount of the

projects cannot exceed the approved credit limit. If the project amount is over the customer’s credit limit, a Credit Limit Adjustment Request

Form 3.2b must be filled out. The Credit Limit Adjustment Request Form 3.2b must then be approved and signed by an

Officer of the Company. This form is then forwarded to the credit administrator, who will then adjust the credit limit in

the system.



Management 09/05/00 11/21/08 003

Rev: Adjusted company name

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SALES AND PROGRAM MANAGEMENT (SECTION 3) 3.2 New Customer Approval RELATED DOCUMENTATION Form – New Customer Approval 3.2 Form – Credit Application 3.2a Form – Credit Limit Adjustment Request 3.2b Procedure – Kick Off / Pre Kick Off Phase Section 3.6

Level 1 – Planning of Product Realization Section 7.1

Procedure – Prototype Kick Off Section 3.12

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SALES AND PROGRAM MANAGEMENT (SECTION 3) 3.3 Project APQP Plan PURPOSE This is a guideline for documenting the scope of all new tool projects. The Project APQP Plan Form 3.3 starts in the quotation process and carries on throughout the tool build. SCOPE Applies to all molds / tools built by Proper Tooling. RESPONSIBILITY It is the responsibility of the sales associate to accurately complete and update the Project APQP Plan Form 3.3 through project kick off. It is the responsibility of the project engineer to finalize, distribute, and maintain the Project APQP Plan Form 3.3 after the project kick off through the end of the program. PROCEDURE Upon kick off of the project, the sales department will: Complete the Contract Review Phase of the Project APQP Plan Form 3.3 as follows: Purchase order number of signed quotation area must be provided. Payment terms must be indicated and agreed upon. Any other non standard services related to feasibility support, warranty, onsite

support, or any other service must be indicated and reviewed to ensure we agree. Complete any missing or revised information in the quotation phase, program

information, contract review phase, and project milestone sections of the Project APQP Plan Form 3.3 and a new quotation is issued to reflect any changes in the scope (this is required any time new CAD data is received for kick off).

Complete any missing information in the plastic part, molding machine, tooling and demolding specifications’ sections of the form.

Complete the project summary section of the Project APQP Plan Form 3.3. Fill out any other information known on the Project APQP Plan Form 3.3. Assign a new APQP revision level on page 1, and log the APQP revision level in the

revision log as the project kick off / Change Order 001. Proceed with the Kick Off / Pre Kick Off Phase Section 3.6 of the Proper Group

International Procedure Manual.

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PROCEDURES MANUAL

SALES AND PROGRAM MANAGEMENT (SECTION 3) 3.3 Project APQP Plan (continued) Upon completion of the kick off phase meeting, it is the responsibility of the program

management department to update the Project APQP Plan Form 3.3, and distribute it to the project team indicated in the distribution section.

As more information is gathered or the project scope changes throughout the life of the

project, the Project APQP Plan Form 3.3 is to be updated and distributed with a Change Order Form 3.15. This is only required when the change affects the information on the APQP.

RELATED DOCUMENTATION Form – Project APQP Plan 3.3 Form – Change Order 3.15 Procedure – Request For Quotation Section 3.1 Procedure – Receipt of Purchase Order Section 3.4 Procedure – New Project Identification System Section 3.5 Procedure – Kick Off / Pre Kick Off Phase Section 3.6 Procedure – Manufacturing Process Plan Phase Section 3.8 Procedure – Prototype Kick Off Section 3.12 Procedure – Tooling Feasibility Study Section 3.16 Level 1 – Customer Focus Section 5.2 Level 1 – Provisions of Resources Section 6.1 Level 1 – Planning of Product Realization Section 7.1 Level 1 – Determination of Requirements Related to the Product Section 7.2.1 Level 1 – Review of Requirements Related to the Product Section 7.2.2

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SALES AND PROGRAM MANAGEMENT (SECTION 3) 3.4 Receipt of Purchase Order PURPOSE This procedure provides specific instructions for the review and acceptance of contractual quality requirements, verifying that the elements of the proposal effort have been mutually agreed upon and ensuring implementation of specific customer quality requirements. SCOPE Applies to all any items manufactured by Proper Group International. RESPONSIBILITY Sales and program management have the overall responsibility for adherence to this procedure. The project costing department must also adhere to this procedure when processing quotations. PROCEDURE When a purchase order is received from a customer, it is stamped with the date received by

the Proper Group International and the purchase order stamp. (The purchase order stamp includes the line spaces to indicate the job number, quote number, and Proper Group International approval).

The sales associate or program manager, additionally signs their initials next to the payment

terms on the purchase order, indicating they have reviewed the terms and has verified the terms are consistent with the quoted or negotiated terms of the project.

The original purchase order is then forwarded to the sales department for new tools or the

administrative associate of program management for existing tools. Depending upon which function is applicable, the following procedures are then performed.

The sales associate or program manager will coordinate any required document changes

with the customer or regulatory authorities.

Existing Projects / Contracts The program manager reviews the following: Payment Terms Delivery Dates Customer Specifications Terms & Conditions


Established Revision Rev #

Sales / Program Management

09/05/00 07/15/09 006

Rev: Updated scope to cover broader product base & sales asc/prg mgr coordinates document changes with customer or regulatory authorities.

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SALES AND PROGRAM MANAGEMENT (SECTION 3) 3.4 Receipt of Purchase Order (continued) If there are any differences between the purchase order and what was agreed to, the sales

associate contacts the customer to resolve the issue(s) prior to acceptance of the order. Depending on the resolution to the issue(s), a new purchase order is received or the first purchase order is accepted.

Once the purchase order is verified as being correct, the program manager fills out the purchase order stamp listing the job number, quote number and their approval signature and processes the order.

A copy of the purchase order is then forwarded to the administrative associate of program

management (for the master file and invoicing). If all documents are correct a Change Order Form 3.15 / 3.15.5 is written to execute the

revision or modification stated on the purchase order.

New Projects Purchase orders are reviewed and approved by the sales associate and sales management

for new projects. Purchase orders are reviewed for their completeness and to specifications as listed under

Project APQP Plan Section 3.3 of the Proper Group International Procedures Manual. If there are any differences between the purchase order and what was agreed to, the sales

associate contacts the customer to resolve the issue prior to acceptance of the order. Once the purchase order is verified as correct, the sales associate fills out the purchase

order stamp listing the job number, quote number, and their approval signature. The purchase order is forwarded to the administrative associate of program management

(for filing and invoicing). NOTE: Some purchase orders have acknowledgements from the customer. If everything is correct, the sales department or the program management department signs the acknowledgement and it is mailed back to the customer. RELATED DOCUMENTATION Form – Change Order 3.15 Form – Change Order 3.15.5 Procedure – Project APQP Plan Section 3.3 Procedure – Tryout Scheduling Section 3.21 Level 1 – Control of Documents 4.2.3 Level 1 – Review of Requirements Related to the Product Section 7.2.2 Reference – Purchase Orders

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SALES AND PROGRAM MANAGEMENT (SECTION 3) 3.5 New Project Identification System PURPOSE To identify a project number for all prototype / production / engineering / and miscellaneous projects requiring use of Proper job tracking system. SCOPE To issue a project number to all projects to ensure proper administrative, fiscal, and management control. RESPONSIBILITY The sales and program management departments are responsible to ensure these guidelines are followed. PROCEDURE Any associate requiring a project identification number must contact the administrative

associate of sales for a new project number. Any associate requiring a project identification number for repair work or engineering

changes (tools not built by Proper) must contact the administrative associate of program management for a new project number.

Project numbers are designated as an 10000 series number for Warren, a 21000 series for

Aerospace, a 30000 series for Croswell, a 40000 & 60000 series for Anderson, and an 80000 series for Proper Technologies.

New Tools (production, class 1 or 2 prototype molds / components) In order for the administrative associate to issue a project number, the Header section of the

Project APQP Plan Form 3.3 or 3.3.5 must be filled out with all available information unless the jobs will be a DL. If job will be a DL, an approved Scope Sheet is required to issue a project number.

Unless the job is a DL, the Project APQP Plan Form 3.3 or 3.3.5 must be accompanied with

the associate quotation and a copy of the purchase order or the customer signed quotation or award letter or

email authorization. (per the Kick Off / Pre Kick Off Phase Section 3.6 & Prototype Kick Off Section 3.12 of the Proper Procedures Manual).

All Other Projects In order for the administrative associate to issue a project number there must be a copy of

the purchase order or the customer signed quotation or award letter or

Issuing Dept.

email authorization. (Per the Kick Off / Pre Kick Off Phase Section 3.6 & Prototype Kick Off Section 3.12 of the Proper Procedures Manual).

Officer


Management 09/05/00 01/05/09 006

Rev: Removed class 3 prototype molds and incorporate components and Aerospace forms.

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SALES AND PROGRAM MANAGEMENT (SECTION 3) 3.5 New Project Identification System The new project number is then added to the New Job Issuance Log Form 3.5. This log is

maintained on the F Drive in the Proper Tooling directory. RELATED DOCUMENTATION Form – New Job Issuance Log 3.5 Form – Change Order 3.15 Form – Change Order Aerospace 3.15.5 Procedure – Kick Off / Pre Kick Off Phase Section 3.6 Procedure – Prototype Kick Off Section 3.12 Procedure – Product Design Section 18.1 Level 1 – Identification and Traceability Section 7.5.3

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SALES AND PROGRAM MANAGEMENT (SECTION 3) 3.6 Kick Off / Pre Kick Off Phase PURPOSE This procedure provides all key design, manufacturing and program management departments with complete background information needed for construction of molds / tools. SCOPE Applies to all production and Class 1 & 2 prototype molds and Aerospace components manufactured by Proper Group International. RESPONSIBILITY The sales department has the overall responsibility for initiating this procedure for Proper Tooling and the manufacturing engineer for Proper Aerospace and completing all documents within 3 days of customer authorization. Project costing has the overall responsibility to adhere to this procedure and complete all the documents. PROCEDURE This procedure encompasses initiation, information gathering, and outcome phases.

The sales associate responsible for the specific customer project will forward the following documentation to the design lab.

Initiation of Meeting

Project APQP Plan Form 3.3 / 3.3.5 Data Request Form 9.1 Cost Authorization from customer

Prior to the kick off / pre kick off meeting, the sales associate will review the total package

for completeness with senior management.



Management 09/05/00 12/15/08 009

Rev: Added Aerospace section & updated to what we are currently doing.

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SALES AND PROGRAM MANAGEMENT (SECTION 3) 3.6 Kick Off / Pre Kick Off Phase

Proper Tooling

The design lab will evaluate the information compared to the quote package and establish a

concept design. Project costing will then initiate the kick off / pre kick off meeting and will send notices to the following associates (via the scheduling department). President Program Manager Director of Operations Design / Engineering Supervisor Sales Associate Vice President of Operations Director of Commercial Group

Proper Aerospace The manufacturing engineer will evaluate the information compared to the quote.

Manufacturing engineer will then initiate the kick off / pre kick off meeting and will send notices to the following associates (via the scheduling department). President Program Manager Manufacturing Representative Sales Associate Vice President of Aerospace

Proper Group International

During the meeting, the following information must be submitted. Project APQP Plan Form 3.3 / 3.3.5 with Header, Manufacturing Tooling Specifications,

and Project Budget sections completed. Data Request Form 9.1 Quoted Drawings or plots Project Background Information New Customer Approval Form 3.2 (if applicable) Open Issues Form 3.6c Preliminary Timeline from the APQP (Proper Tooling Only)

NOTE: It is not necessary to have data to initiate this meeting.

Discuss APQP plan (customer input should be available).

Topics of Discussion

Complete review of all documents brought to the meeting. General outline of what the company is manufacturing. Review Timing and resource plan to assure resources have been identified to support all

operations and meet the delivery commitment.

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SALES AND PROGRAM MANAGEMENT (SECTION 3) 3.6 Kick Off / Pre Kick Off Phase (continued) Review and establish if outside subcontracting is required. Review customer expectations. Review project requirements including any special features, new technology and risks.

The following paperwork will be completed upon the outcome of this meeting:

Outcome

Project APQP Plan Form 3.3 / 3.5 – updated with any changes resulting from the meeting.

Open Issues Form 3.6c Timeline will be developed in the Proper Scheduling System

Upon receipt of kick off CAD data, project costing will complete Change Order Form 3.15 /

3.15.5 number 001 to release data and formally kick off the project.. Distribution for this change order is indicated in the Distribution List.

Additional Sales Department Responsibilities The Proper Program Management Manual for the specific project will be created. Distribution List (Hard Copy)

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Obsolete Drawings x New Customer Approval x Full Size Plots x Original Quote Package x Change Order 001 Distribution x x x x x x x x X x x Project APQP Plan x x x x Data Request Form x x x X Open Issues x x x x Timeline x x x x The forms in green are available on the system for all to review.

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PROCEDURES MANUAL

SALES AND PROGRAM MANAGEMENT (SECTION 3) 3.6 Kick Off / Pre Kick Off Phase

Prototype Classifications

Class 1 - Full Production Intent Prototype Mold Gating to simulate production including hot runner systems if indicated on quotation. Includes first set up and (10) pieces. All mold actions are mechanized to simulate production. Mold is self-contained having its own ejector system and mold base. Tolerancing and part quality is similar to production standards. Mold is CMM inspected if requested. Plastic material, custom packaging and freight are not included. Mold is not CMM inspected; however, parts are checked for overall size and part features. Class 2 - Machined Prototype Non Mechanized Gating similar to production without the use of hot runner systems. Gating location is limited

to mold size and configuration. Includes first set up and (10) pieces. All part features requiring mold action will be loose pieces. Mold will be constructed for “Proper Group International mud unit” if size permits or self

contained with its own mold base and ejector system. Tolerancing and part quality is similar to production. Due to loose inserts, processing may be hampered creating shrink and surface concerns. Plastic material, custom packaging and freight are not included. Mold is not CMM inspected; however parts are checked for overall size and part features. RELATED DOCUMENTATION Form – New Customer Approval 3.2 Form – Project APQP Plan 3.3 Form – Project APQP Plan 3.3.5 Form – Open Issues 3.6c Form – Change Order 3.15 Form – Change Order 3.15.5 Form – Data Request 9.1 Procedure – New Customer Approval Section 3.2 Procedure – Project APQP Plan Section 3.3 Procedure – New Project Identification System Section 3.5 Procedure – Concept Phase Section 3.7 Procedure – Manufacturing Process Plan Phase Section 3.8 Procedure – Post Sampling Phase Section 3.10 Procedure – Post Shipment Phase 3.11 Procedure – Prototype Kick Off Section 3.12 Procedure – Timelines Section 3.14 Procedure – Tooling Feasibility 3.16

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PROCEDURES MANUAL

SALES AND PROGRAM MANAGEMENT (SECTION 3) 3.6 Kick Off / Pre Kick Off Phase (continued) RELATED DOCUMENTATION Procedure – In Process Inspection Section 6.1 Procedure – Incoming Data & Naming Convention Section 9.1 Procedure – Design FMEA Section 10.2 Procedure – Preventive Maintenance Section 11.2 Procedure – Maintenance Requests Section 11.3 Procedure – Preliminary Mold Design Phase Section 15.1 Procedure – Final Mold Design Phase Section 15.2 Procedure – Product Design Section 18.1 Procedure – Product Design Verification and Validation Section 18.3 Level 1 – Customer Focus Section 5.2 Level 1 – Provisions of Resources Level 1 – Planning of Product Realization Section 7.1 Level 1 – Determination of Requirements Related to the Product 7.2.1 Level 1 – Review of Requirements Related to the Product Level 1 – Design and Development Planning Section 7.3.1 Level 1 – Design and Development Inputs Section 7.3.2 Level 1 – Design and Development Review Section 7.3.4 Level 1 – Analysis of Data Section 8.4 Level 1 – Continual Improvement Section 8.5.1 Level 1 – Preventive Action Section 8.5.3 Reference – Proper Tooling Schedule Capacity System

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PROCEDURES MANUAL

SALES AND PROGRAM MANAGEMENT (SECTION 3) 3.7 Concept Phase PURPOSE This procedure provides a means of review of concept design and kick off of preliminary design. SCOPE Applies to all production molds / tools manufactured by Proper Tooling. RESPONSIBILITY The engineering department has the overall responsibility for initiation and content of the meeting. PROCEDURE

Initiation of Meeting The engineering manager will issue a notice to the following associates to attend the

meeting: Program Manager (attendance optional) General Manager or President Design Department Scheduling Department

This meeting is to occur per the Proper Tooling Scheduling Capacity System. The intention of this meeting is to review the initial concept designs for the mold to be

manufactured. Through this review of the concept design, completion of the following information will be

obtained: Review for manufacturing of the concept design. Modify and create any enhancements / changes to the concept design. Review Open Issues Form 3.6c for completion and any additions. Review the Proper Schedule for any modifications Review any additional requirements or engineering changes that were introduced. Review Tooling Feasibility Study Form 3.16 (if required)

Outcome The following will be completed upon the outcome of this meeting: A modified timeline (if required) Updated Open Issues Form 3.6c (if required) Clear direction for the design department to finalize preliminary designs for customer

submission. Review capacity / backlog issues regarding the project.



Management 09/05/00 12/15/08 006

Rev: Eng has overall resp, Form 3.6d omitted, using Proper Scheduling Capacity System

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PROCEDURES MANUAL

SALES AND PROGRAM MANAGEMENT (SECTION 3)

Additional Program Management Responsibilities Complete the open issues on the Open Issues Form 3.6c that would result in delays of the

program. Close out any open feasibility issues resulting in project changes. (Reference Tooling

Feasibility Study Section 3.16 of the Proper Tooling Procedures Manual). Distribute a Change Order Form 3.15 if the projects customer date is changing. Design Department Responsibility If there are additions or changes to the Open Issues Form 3.6c or timelines, the design

department will issue an email per the distribution list that updates have been made.

Distribution List Director, Operations / Job File Quality Program Manager Design EDM CNC Scheduling Manufacturing RELATED DOCUMENTATION Form – Project APQP Plan 3.3 Form – Open Issues 3.6c Form – Change Order 3.15 Form – Tooling Feasibility Study 3.16 Procedure – Prototype Kick Off Section 3.12 Procedure – Timelines Section 3.14 Procedure – Tooling Feasibility Study Section 3.16 Procedure – Design FMEA Section 10.2 Level 1 – Planning of Product Realization Section 7.1 Level 1 – Design and Development Planning Section 7.3.1 Level 1 – Design and Development Review Section 7.3.4 Level 1 – Preventive Action Section 8.5.3 Reference – Proper Tooling Scheduling Capacity System

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PROCEDURES MANUAL

SALES AND PROGRAM MANAGEMENT (SECTION 3) 3.8 Manufacturing Process Plan Phase PURPOSE To develop a final manufacturing plan for the construction of the mold outlining all operations required for successful completion (also know as the control plan – reference Tool Construction Control Plan Section 10.1 of the Proper Group International Procedures Manual).

SCOPE

Applies to all production and Class 1 & 2 prototype molds / tools manufactured by Proper Tooling, when deemed required at the concept meeting. RESPONSIBILITY The scheduling department is responsible for initiating the process plan phase.

PROCEDURE

Initiation of Meeting The manufacturing process phase meeting is scheduled when deemed necessary at the

concept meeting. The scheduling department will add the process meeting to the timeline. Three days prior to the planned date for the meeting, the scheduling department contacts

the design department to confirm their readiness for this meeting and sends out a meeting notice accordingly.

The scheduling department will notify the following associates for attendance of this

meeting: Design Supervisor General Manager Program Manager CNC Department EDM Department Manufacturing Department Representative Detail Department



Management 09/05/00 12/15/08 008

Rev: Omitted Class 3 prototype mold & form 3.6b, 3.6d & 3.9 references

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PROCEDURES MANUAL

SALES AND PROGRAM MANAGEMENT (SECTION 3) 3.8 Manufacturing Process Plan Phase Through this review of the manufacturing process plan meeting, the following information

will be brought by the department as noted: Full size preliminary designs (design department) Completed Project APQP Plan Form 3.3 for reference use (program management) Master Schedule (scheduling department) Open Issues Form 3.6c (program management)

The core manufacturing group will be in charge of this meeting. During this meeting the following topics will be discussed: Review of Open Issues Form 3.6c Overall manufacturing plan Any special manufacturing processes Any outsourcing and/or subcontracting requirements Any overtime or premium overtime needs to be determined and authorized Any redevelopment of the design Any enhancements the team would like to have implemented Review and update of Project APQP Plan – Budget Section Form 3.3, if required

Outcome The following paperwork will be completed upon the outcome of this meeting: If required, the timeline is updated. Any open issues must be added and completed by program management. The Project APQP Plan – Budget Section Form 3.3 and Syteline Budget are updated to

include hours / costs for the mold as built per the process meeting. RELATED DOCUMENTATION Form – Project APQP Plan 3.3 Form – Open Issues 3.6c Procedure – Prototype Kick Off Section 3.12 Procedure – Tooling Feasibility Study Section 3.16 Procedure – Tool Construction Control Plans Section 10.1 Procedure – Process FMEA Section 10.3 Level 1 – Planning of Product Realization Section 7.1 Level 1 – Design and Development Planning Section 7.3.1 Level 1 – Design and Development Review Section 7.3.4 Level 1 – Preventive Action Section 8.5.3 Reference – Master Schedule Reference – Syteline Budget

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PROCEDURES MANUAL

SALES AND PROGRAM MANAGEMENT (SECTION 3) 3.8.5 Manufacturing Process Plan Phase - Aerospace PURPOSE To develop a manufacturing plan for production of parts and assemblies controlled a First Article

Inspection Process. The construction and/or assemble of these products will be controlled and

directed by a Work Order Router Form 3.8.5.

SCOPE Proper Group International Companies RESPONSIBILITY Manufacturing Engineering is responsible for initiating and developing the Work Order Router.

Quality management is responsible for approving the plan.

PROCEDURE Manufacturing engineering shall create a Work Order Router using Form 3.8.5 that details the

manufacture and/or assembly of parts controlled the First Article Inspection process. They will verify the revision levels of the customer drawing documentation and/or digital

model to ensure it is in accordance with the Purchase Order. The quality manager will be responsible to review the routers prior to the release to

manufacturing. Manufacturing Engineering shall maintain Work Order Revisions as required to incorporate

Changes in Work Scope, Engineering Changes and/or Corrective Actions. Any revisions will be defined in the Work Order Revision Section with Revision Level and Date of incorporation.

The Work Order Router Form 3.8.5 will define, initiate and verify all specifications for material,

processing, special environmental considerations, general machining practices and inspection requirements.

The Verification Method for purchased product will be defined on the Work Order Router

Form 3.8.5.. If certification is required, they will be compared to the customer specification and/or

desired standards. The review will verify that the elements of the certification match the specifications.

Issuing Dept. Officer: Established Revision Rev # Sales / Program

Management 12/15/08 07/07/09 003

Rev: Key characteristics will be clearly identified on Form 3.8.5 in the manufacturing router sequence.

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The Work Order Router Form 3.8.5 will also identify Key Characteristics identified by our customer or deemed to have a significant influence on product fit, performance, service life or manufacturability.

3.8.5 Manufacturing Process Plan Phase – Aerospace These identifications will be noted on the Work Order Router Form 3.8.85 in the

manufacturing router sequence when they apply. Validation / Inspection Criteria will be specified on the Work Order Router Form 3.8.5 per the

customer standards, design standards, purchase order requirements and/or as we deem necessary. The criteria should identify the specifications, the inspection method, frequency of

inspection, and criteria for inspection and/or rejection. The results are recorded on the Work Order Router Form 3.8.5

Inspection requirements may include process capability methods, statistical process control,

Design of Experiments and inspection of key characteristics.

Processes may include product identification or serialization as identified by the customer standards, specifications or purchase order.

If serialization is required, the Work Order Router Form 3.8.5 will identify and track the serial

numbers used for each part manufactured as required by the customer requirements.

Serial numbers can not be reassigned, even if a product is scrapped during the manufacturing process.

Manufacturing Work Order Routers Form 3.8.5 prior to the First Article Inspection may be

changed by the manufacturing engineer, supervisor and/or programmer.

These changes may only affect manufacturing methods and can not affect the customer specifications.

All changes must be documented on the Work Order Router Form 3.8.5 with the initials

of the person making the change.

Manufacturing Work Order Routers Form 3.8.5 after the First Article may be changed for part quantities and delivery only by the manufacturing engineer and/or supervisor.

These changes must be documented on the Work Order Router Form 3.8.5 with the

initials of the person making the change.

Manufacturing Work Order Routers Form 3.8.5 after the First Article Inspection that require changes to the process of procedures can only be approved by the quality manager.

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These changes must be documented on the Work Order Router 3.8.5 with the initials of the person making the change and the First Article Inspection / Certification may need to be revised per the customer standards and requirements.

3.8.5 Manufacturing Process Plan Phase – Aerospace The completed Work Order Routers Form 3.8.5 are to be returned to the quality manager

when all operations are complete.

The completed Work Order Routers Form 3.8.5 will be scanned and the electronic data stored under the job files.

RELATED DOCUMENTATION Form – Work Order Router 3.8.5 Procedure – First Article Inspection Section 6.9 Level 1 – Planning of Product Realization Section 7.1 Level 1 – Review of Requirements Related to the Product Section 7.2.2 Level 1 – Control of Production and Service Provision Section 7.5.1 Level 1 – Validation of Processes for Production and Service Provision Section 7.5.2

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PROCEDURES MANUAL

SALES AND PROGRAM MANAGEMENT (SECTION 3) 3.9 Customer Property PURPOSE This procedure provides specific instructions for the care with customer property while it is under Proper Group International’s control or being used by Proper Group International. SCOPE Applies to customer property located at Proper Group International. RESPONSIBILITY Program management has the overall responsibility for adherence to this procedure. PROCEDURE Customer supplied property is received in two types:

Electronic Information Documents Data Standards

Supplied Product Plastic Resin Packaging Gaging EOA Tooling Secondary Equipment Purchased Components Mating Components

Preliminary Control

All associates of Proper Group International sign Confidentiality Agreements to ensure the

safeguard of customer information.

Proper Group International e-mail systems restricts the incoming and outgoing file size to 12 mb to prevent electronic information to be transferred uncontrolled.

All customer data, electronic or in paper format, are logged into the data management

department.



Management 03/30/09 Release

Rev: New Procedure

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PROCEDURES MANUAL

SALES AND PROGRAM MANAGEMENT (SECTION 3) Ongoing Control All customer data is stored in the Proper Group International data servers under the

customer name, month, and year.

This data is retained in a quarantined system not released to Proper Group International associates.

Customer standards are logged in at the engineering department with only (2) controlled

copes released. (Reference Engineering Manual – Customer Standards Section 2.19) One for the engineering group. One for the manufacturing group.

Updates when received are logged and obsolete copies are destroyed.

Upon completion of customer information, disposition is performed per the Record Retention

and Control Procedure 7.1. Supplied Product The program manager is notified when the customer’s property arrives. The program

manager will give direction for the appropriate location to store the product.

If changes to the product are required, a Change Order Form 3.15/3.15.5 is completed and distributed by the program manager.

Copies of the incoming shipper or bill of lading are forwarded to the program management

administrative associate to file in the master job file. If Proper Tooling receives customer supplied product, the article is identified with a Proper

Group International Job number and is distributed to the appropriate location for use. Customer Tools All incoming molds received at a Proper Group International facility must be inspected prior

to removal from the transport vehicle. Any damages noticeable must be documented on the transporter documents received.

The program manager is notified when the customer’s property arrives. The program


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PROCEDURES MANUAL

SALES AND PROGRAM MANAGEMENT (SECTION 3) 3.9 Customer Property (continued) If changes to the product are required, a Change Order Form 3.15 is completed and

distributed by the program manager.

Copies of the incoming shipper or bill of lading are forwarded to the program management administrative associate to file in the master job file.

RELATED DOCUMENTATION Form – Change Order 3.15 Form – Change Order 3.15.5 Procedure – Record Retention and Control Section 7.1 Level 1 – Customer Property Section 7.5.4 Level 3 – Customer Standards (Engineering Manual) Section 2.19

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PROCEDURES MANUAL

SALES AND PROGRAM MANAGEMENT (SECTION 3) 3.10 Post Sampling Phase PURPOSE This procedure is to review results from initial sampling and finalize a plan for mold completion.

SCOPE

Applies to all production molds / tools, related product, and unsuccessful prototype tryouts

manufactured by the PME Companies.

RESPONSIBILITY It is the responsibility of the program manager to ensure this meeting is scheduled within one working day of initial sampling. The meeting notice will be sent out by the process engineer.

PROCEDURE

Initiation of Meeting The program manager will notify the following associates for attendance of this meeting: Program Manager / Project Engineer (Director of Project Management & Costing) Design Leader (Engineering Supervisor) Mold Leader (Manufacturing Supervisor) Quality (Quality Technician) Process Engineer (Process Technician)

NOTE: If the designated associates are unable to attend for any reason than the associate’s designated in parentheses are to attend in their place.

During the meeting, the following information will be brought by the department as noted: Painted / marked up parts (program management) Initial quality inspection (quality) Mold Tryout Open Issues Form 12.3 (process engineer) Open Issues Form 3.6c (process engineer)

Outcome Discussion and action to complete the subject tool. The following paperwork will be completed upon the outcome of this meeting: Signed / updated Change Order Form 3.15 will be distributed by the program manager, if

required.

Updated Mold Tryout Open Issues Form 12.3 to be distributed by the process engineer.



Management 09/05/00 10/01/06 004

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Update Open Issues Form 3.6c to be distributed by the process engineer. 3.10 Post Sampling Phase

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Open Issues x x x x Change Order x x x x x x x Mold Tryout Open Issues x x x x x x RELATED DOCUMENTATION Form – Open Issues 3.6c Form – Change Order 3.15 Procedure – Prototype Kick Off Section 3.12 Procedure – Mold Certification & Acceptance Section 12.1 Procedure – Mold Tryout Open Issues Section 12.3 Level 1 – Preventive Action Section 8.5.3

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SALES AND PROGRAM MANAGEMENT (SECTION 3) 3.11 Post Shipment Phase PURPOSE This procedure provides follow up analysis upon completion of tooling. SCOPE Applies to all production molds / tools and related product manufactured by the PME Companies. RESPONSIBILITY It is the responsibility of the director of project management & costing for adherence to this procedure.

PROCEDURE

Initiation of Meeting The director of project management and costing will schedule this meeting within ninety

days after final shipment date of the mold / tool as recorded on the shipping log. The scheduling department will send a meeting notice to the following associates for

attendance of this meeting: Director of Operations Director of Engineering / Manufacturing Manufacturing Supervisor Mold Leader Design Associate Core Manufacturing Associate Program Manager Account Manager

The following information is brought and discussed during this meeting: Job financial and delivery information is provided by program management. Financial

information will include Total Sales Value, Profit, PCGP, Budget to actual comparison. Prime costs to be broken down showing labor, material and outside services.

The Project Overview Form 3.11 is reviewed and additional comments are documented and signed by all attendees.

Change Order (Form 3.15) history is reviewed. Notes taken during project from design and manufacturing are reviewed. Notes taken at Post Sampling meeting are reviewed.



Management 09/05/00 10/01/06 005

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SALES AND PROGRAM MANAGEMENT (SECTION 3) 3.11 Post Shipment Phase

Outcome All Open Issues Form 3.6c that are determined to drive changes to PME processes,

procedures, and standards are added to the Open Issues Form 3.6c. Customer specific requirements that are not covered in the original quoting process are

forwarded to the estimating department to ensure they are part of the standards used for further quoting.

Complete Project Overview Form 3.11 is submitted to the President at the time of the operations meeting for discussion and possible additional action.

Distribution of Completed Project Overview Form 3.11 Program Management File President RELATED DOCUMENTATION Form – Open Issues 3.6c Form – Project Overview 3.11 Form – Change Order 3.15 Procedure – Operations Meeting Section 2.4 Procedure – Prototype Kick Off Section 3.12 Level 1 – Planning of Product Realization Section 7.1 Level 1 – Preventive Action Section 8.5.3

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SALES AND PROGRAM MANAGEMENT (SECTION 3) 3.12 Prototype Kick Off PURPOSE This procedure provides all key manufacturing departments with complete background information needed for construction of all classes of prototype tooling and parts. SCOPE Applies to all class 2, 5 & 6 prototype tools and parts manufactured by Proper Technologies RESPONSIBILITY The sales department has the overall responsibility for initiating this procedure. Program management has the overall responsibility to adhere to this procedure and complete all the documents. PROCEDURE This procedure encompasses initiation, information gathering and outcome phases. Initiation of Meeting The sales associate responsible for the specific customer project will initiate the kick off / pre

kick off meeting and will send notices to the following associates: General Manager of Proper Technologies Design Supervisor (if required) Customer Representative (if required)

During the meeting, the following information must be submitted by the sales associate: Completed Approved Quotations and/or Purchase Order Drawings and/or Data Data Review Forms Obsolete or Quoted Drawings (identified as for Quote Only) Project Background Information New Customer Approval Form 3.2 (if applicable) Project APQP Plan Form 3.3 Open Issues Form 3.6c

NOTE: It is not necessary to have data to initiate this meeting.



Management 09/05/00 12/15/08 007

Rev: Omitted Class 1,3 & 4 and updated procedure.

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3.12 Prototype Kick Off

Topics of Discussion Complete review of all documents brought to the meeting. General outline of what the company is manufacturing. Review timing. Review and establish if outside subcontracting is required. Outcome The Open Issues Form 3.6c must be completed upon the outcome of this meeting. Upon receipt of kick off CAD data, the manager of product development & RP tooling will

complete the Change Order Form 3.15 number 001 to release data and formally kick the project off.

Distribution List Class 4, Class 5, & Class 6 Prototypes

Sale

s

Gen

eral

M

anag

er

– Pr

oper

Te

chno

log

ies

Pr

ojec

t Fi

le

Des

ign

Drawings / Data X Data Review Form X X X Obsolete Drawings X New Customer Approval (if applicable) X X X Open Issues X X X X Project APQP Plan X X X X

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SALES AND PROGRAM MANAGEMENT (SECTION 3) 3.12 Prototype Kick Off Prototype Classifications

Class 2 - Machined Prototype Non Mechanized Gating similar to production without the use of hot runner systems. Gating location is limited

to mold size and configuration. Includes first set up and (10) pieces. All part features requiring mold action will be loose pieces. Mold will be constructed for “Proper Group International mud unit” if size permits or self

contained with its own mold base and ejector system. Tolerancing and part quality is similar to production. Due to loose inserts, processing may be hampered creating shrink and surface concerns. Plastic material, custom packaging and freight are not included. Mold is not CMM inspected; however parts are checked for overall size and part features. Class 5 – Spray Metal Prototype Injection Mold Mold is constructed utilizing a master such as a SLA pattern. Mold is only good for parts with low amount of ribbing. Life expectancy is guaranteed at 50 parts. Additional parts beyond 50 can usually be

accomplished, however, piece costs are usually increased due to additional part trimming. Plastic resins of abrasive chemistry could reduce the life expectancy of the mold. Engineering changes are typically not feasible. All part features requiring mold action will be loose pieces or hand machined after molding. Parts are ejected using air; an ejector system is not incorporated. Tolerancing and part quality is approximately 50% of a Class 1 prototype. Process molding cannot be accomplished with this prototype. Mold is not CMM inspected; however parts are checked for overall size and part features. Initial set up is charged as a first part run set up and is not included in the tool cost. Plastic material, custom packaging and freight are not included. Mold remains the property of Proper Group International.

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SALES AND PROGRAM MANAGEMENT (SECTION 3) 3.12 Prototype Kick Off (continued) Class 6 - Rapid Prototype Tooling Mold is used for prototype parts not requiring laboratory testing. All parts from rapid prototype tooling are of urethane base material. Rapid prototype tooling life is guaranteed at 20 parts. Additional parts beyond 20 can

usually be accomplished, however, piece costs are usually increased due to additional part trimming.

Parts are constructed from SLA or LOM patterns. Tolerancing and part quality is acceptable for fit and finish use. Parts are not inspected, except for completeness and surface quality. Set up cost is charged regardless of part quantities. Urethane material and packaging are included in the piece cost. Freight is not included. Mold remains the property of the Proper Group International. RELATED DOCUMENTATION Form – New Customer Approval 3.2 Form – Project APQP Plan 3.3 Form – Project Budget 3.6b Form – Open Issues 3.6c Form – Kick Off Phase Timeline 3.6d Form – Change Order 3.15 Procedure – New Project Identification System Section 3.5 Procedure – Concept Phase Section 3.7 Procedure – Manufacturing Process Plan Phase Section 3.8 Procedure – Pre Sampling Phase Section 3.9 Procedure – Post Sampling Phase Section 3.10 Procedure – Post Shipment Phase Section 3.11 Level 1 – Review of Requirements Related to the Product Section 7.2.2

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SALES AND PROGRAM MANAGEMENT (SECTION 3) 3.13 Project Scheduling Meeting PURPOSE To keep all involved personnel informed of the progress and any issues throughout the build of a tool to ensure on-time deliveries to meet our customers’ requirements. SCOPE This procedure is to be implemented for all Proper Group International facilities. RESPONSIBILITY It is the responsibility of the director of operations to ensure that the weekly meetings are held. PROCEDURE The project scheduling team is a cross function team made up of: Program Managers Vice President of Operations Associate(s) from design, manufacturing, and scheduling.

This team has meetings on a scheduled weekly basis to discuss and review the status of

every project at the facility. Issues that are discussed: The progress of each project Any problems at any stage of the progress Potential problems involving any non-conformances and the corrective action Solutions Timing charts are available for review of each project (Reference Timelines Section

3.14) Corrections made after final inspection Customer concerns General product quality Continued quality improvement Delivery (delivery is normally to first sample date) All previous week issues are discussed to verify that corrective actions have been taken



Management 09/05/00 12/15/08 007

Rev: Omitted corrective actions & nonconforming areas as being discussed during this mtg.

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SALES AND PROGRAM MANAGEMENT (SECTION 3) 3.13 Project Scheduling Meeting Scheduling meeting notes are recorded and distributed to all necessary personnel which

records/lists all problem concerns, corrective action and necessary follow-up. These notes are published on the Proper Group International Job Forecast.

The administrative associate of program management keeps the master records from the

Proper Group International Job Forecast / Notes. The general managers have the responsibility and control to prevent further processing,

delivery or installment of nonconforming products or tooling until the deficiency or unsatisfactory condition has been corrected.

RELATED DOCUMENTATION Procedure – Timelines Section 3.14 Procedure – 8-Discipline Problem Solving Method Section 3.19 Procedure – Product Design Section 18.1 Level 1 – Provisions of Resources Section 6.1 Reference – Proper Job Forecast

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SALES AND PROGRAM MANAGEMENT (SECTION 3) 3.14 Timelines PURPOSE To standardize the procedure for implementation and distribution of project timelines. SCOPE This procedure is to be implemented for all Proper Tooling facilities. RESPONSIBILITY It is the responsibility of the scheduling department to initiate and maintain ALL paperwork listed under the following procedures for the internal scheduling system. PROCEDURE The following procedure is used for new production molds and Class 1 through Class 3 prototypes:

Initiation of a New Project During the kick off phase of a new project, a timeline in the Proper Tooling’s Scheduling

Capacity System is established. The account manager in charge of the project is responsible to ensure the timeline is

complete for kickoff. See the Kick Off / Pre Kick Off Phase Section 3.6 of the Proper Tooling Procedures Manual.

The Concept Phase Section 3.7 of the Proper Group International’s Procedures Manual will

undergo a review and incorporate any modifications to the timeline. At this time the scheduling department will take over responsibility for documenting and

maintaining the schedule.

Customer Time Lines The customer will receive the initial timeline compiled at the Kick Off Phase. The program

manager is responsible for distribution to the customer. The program manager is responsible to provide all updates for the customer timeline by

Monday morning each week.



Management 09/05/00 12/15/08 004

Rev: Program mgr is resp for updates to the customer, & omitted reference to procedure 3.8

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SALES AND PROGRAM MANAGEMENT (SECTION 3) 3.14 Timelines Customer distribution will be on Monday of each week unless there is a holiday, which will

then be the next business day. Distribution will be by primarily email, fax or internet dependent on the customer’s

requirements. RELATED DOCUMENTATION Procedure – Kick Off / Pre Kick Off Phase Section 3.6 Procedure – Concept Phase Section 3.7 Procedure – Project Scheduling Meeting Section 3.13 Level 1 – Provisions of Resources Section 6.1 Level 1 – Customer Communication Section 7.2.3 Reference – Proper Scheduling Capacity System Reference – Timelines

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SALES AND PROGRAM MANAGEMENT (SECTION 3) 3.15 Change Orders PURPOSE This is a company wide procedure to document and maintain a record of any changes to a mold/tool, which occurs after the start of construction as well as the kick off of a new tool, repair or change of an existing tool. SCOPE This applies to all changes to a mold/tool or new project kick off within Proper Tooling. RESPONSIBILITY It is the responsibility of the program manager to oversee any activities of change orders for changes. New project kick off change orders are the responsibility of the commercial group. PROCEDURE The program manager generates a Change Order Form 3.15 describing all the work to be

performed. The Change Order Form 3.15 must list the job number and suffix, delivery dates, data dates, and quotation number, if applicable.

Change orders for changes or repairs that exceed 2 weeks or change / establish new

delivery dates during base tool build, require the scheduling system to be updated.

The program manager must also put the change order label on the marked up parts (if applicable) for that particular change. These labels will document the parts with the Change Order Form 3.15.

The Change Order number is determined by what job number and how many changes have

been made to the particular job. Change orders are written in sequence to maintain accurate records of a particular project. All completed Change Order Form 3.15 are located in directory:

F:\Design To locate the last change on a job, you can look in this directory

Change Order Use There are four primary uses of Change Order Form 3.15. Engineering Change Kick-Off Change Orders (that are charged to the customer) Time & Material Change Orders No Charge Change Orders New Job Kick Off (Change Order Form 3.15 issued by the commercial group)



Management 09/05/00 03/06/09 012

Rev: Now accept written form of authorization.

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SALES AND PROGRAM MANAGEMENT (SECTION 3) 3.15 Change Orders (continued) Engineering Change and Chargeable Repair Kick-Off Change Orders (with costs) The program manager generates a Change Order Form 3.15 describing all the work to be

performed. The Change Order Form 3.15 must list the following: Change Order Number Job Number Suffix Delivery Dates Data Dates Quote Number Additional Costs to “Price” must be checked YES Additional “Delivery” must be checked YES or NO Change / Repair must be checked Yes for all items that are chargeable

Before the Change Order Form 3.15 can be kicked-off, a signed copy by the customer on

the quotation or a purchase order or some form of written authorization must be obtained. The white copy of the Change Order Form 3.15 is forwarded to the program management

administrative associate for processing along with a signed engineering change quotation, purchase order or some form of written authorization.

All other copies are distributed to the correct departments as listed on the form. In general, sketches, CAD screen dumps, and any additional information that may help

implement the change are attached. Time & Material Change Orders The program manager generates a Change Order Form 3.15 describing all the work to be

performed. The Change Order Form 3.15 must list the following: Change Order Number Job Number Suffix Delivery Dates Data Dates For Quote Number “T&M” must be placed in this section (time and material) Additional Costs to “Price” must be checked YES Additional “Delivery” must be checked YES or NO Change / Repair must be checked Yes for all items that are chargeable

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SALES AND PROGRAM MANAGEMENT (SECTION 3) 3.15 Change Orders (continued) The customer must issue a purchase order number, sign the approved engineering

quotation, or provide some form of written authorization to proceed before the Change Order Form 3.15 can be issued.

In cases where emergency repairs are required on off shift hours, the proper signatures may

be waived; however, customer authorization must be obtained prior to the mold leaving the facility.

The white copy of the Change Order Form 3.15 along with a signed quotation, purchase

order or provide some form of written authorization to proceed is forwarded to the program management administrative associate for processing. All other copies are distributed to the correct departments as listed on the form.

Two weeks after the completion of the time and material work, the program management

administrative associate generates a Job Inquiry Report. This report along with the “T&M” Change Order Form 3.15 is forwarded to the assigned program manager to generate a quotation.

The program manager generates a quotation, which is then sent to the customer to obtain

sign off. No Charge Change Orders This type of change order generally covers three areas: Warranty – molds that were accepted by the customer and returned, or dispatched

technicians correct a defect in the product. Completion / Finalization – molds that are not completed and accepted by the customer.

This typically means minor corrections after the first tryout or after incorporated engineering changes. This type of change order is used throughout the mold construction and certification process. This includes finalization and texture preparation.

Non Performance – failures caused by not following Proper Tooling standards or procedures. This typically means corrections that were not completed on a previous change order. This may also be used in place of Warranty when the failure was caused by not following Proper Tooling Change Order Form 3.15 standards or procedures or problems posed from a design or manufacturing failure. NOTE: In some cases the change order may involve “chargeable items” and “non

chargeable items”. In this case, each item on the change order is marked for the appropriate status.

NOTE: When a “non performance or warranty” change order is issued, the program

manager must include the estimated hours and the estimated outside service and material cost that relates to the items.

The program manager generates a Change Order Form 3.15 describing all the work to be performed.

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SALES AND PROGRAM MANAGEMENT (SECTION 3) 3.15 Change Orders (continued) The Change Order Form 3.15 must list the following: Change Order Number Job Number Suffix Delivery Dates Data Dates Additional Costs to “Price” must be checked NO Additional “Delivery” must be checked YES or NO

The white copy of the Change Order Form 3.15 is forwarded to the program management

administrative associate for processing. All other copies are distributed to the correct departments as listed on the form.

Any additional information will be attached including sample parts to aid in the correction or

modification.

Distribution Once the form is generated, the program manager makes the colored copies for distribution. White Copy - to the program management administrative associate for inputting into the

computer system and is then filed in the master job files. Yellow Copy - to the mold leader. Pink Copy - to the plant foreman Gold Copy - to the program manager Green Copy - to design. Blue Copy - to quality White Copy – to core manufacturing White Copy – to data management White Copy – to general manager White Copy – to Vice President of Operations White Copy – to scheduling

3.15 Change Orders RELATED DOCUMENTATION Form – Change Order Form 3.15 Procedure – Receipt of Purchase Order Section 3.4 Procedure – Kick Off / Pre Kick Off Phase Section 3.6 Procedure – Post Sampling Phase Section 3.10 Procedure – Post Shipment Phase Procedure – Prototype Kick Off Section 3.12 Procedure – Corrective Action Reporting & Response Section 3.18 Procedure – Engineering Change Worksheet 3.25 Procedure – In Process Inspection Section 6.1

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SALES AND PROGRAM MANAGEMENT (SECTION 3) RELATED DOCUMENTATION (continued) Procedure – Incoming / In Process Components & Material Inspection & Non Conformity Guidelines Section 6.2 Procedure – Servicing Section 6.5 Procedure – Welding Section 6.8 Procedure – Incoming Data & Naming Convention Section 9.1 Procedure – Mold Certification & Acceptance Section 12.1 Procedure – Mold Tryout Open Issues Section 12.3 Level 1 – Customer Communication Section 7.2.3 Level 1 – Control of Production and Service Provision Section 7.5.1

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SALES AND PROGRAM MANAGEMENT (SECTION 3) 3.16 Tooling Feasibility Study PURPOSE This is a guideline for documenting product / tooling feasibility issues. SCOPE This is an engineering standard for defining the steps involved in product / tooling feasibility prior to releasing the data to the manufacturing groups. RESPONSIBILITY The associate supervisor of engineering and program management has the responsibility of ensuring that the tooling feasibility study is performed and completed thoroughly. DEFINITIONS Product / Tooling Feasibility – the study of supplied product designs in regards to the ability to manufacture tooling is such a way that the design and integrity of the tool allow for the manufacturing of product that will meet all customer or internally driven standards. Advanced Engineering / Design Lab – the study of product and tooling concerns prior to the releasing data to the design and manufacturing groups. PROCEDURE Following is the procedures and descriptions for filling out the Tooling Feasibility Study Form 3.16. General Information & General Tool Build Description If a feasibility study is requested on a Project APQP Plan 3.3, the information gathered at

the “kick off” meeting is used to complete a feasibility study by the engineering department. If a feasibility study is requested prior to receiving a Project APQP Plan 3.3 and job

awarded, it is at the discretion of the sales associate to determine the extent of the needed feasibility. This information is to be forwarded to the Design Lab to begin initial feasibility.

Data Inspection Incoming data is reviewed for supplied die vectors and parting lines. A tip intersection point is established using nominal body position coordinates if possible in

order to have a global reference to the part in its original body position. Issuing Dept. Officer


Sales / Program Management

09/05/00 01/12/09 003

Rev: Design Lab now, inc data rvwd for die vectors/PL, Feas issues closed with cust.

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SALES AND PROGRAM MANAGEMENT (SECTION 3) 3.16 Tooling Feasibility Study (continued) A line of draw is established and tip lines are drawn to show the tool or mold position for

manufacturing. The line of draw and parting lines from customer’s data will be used if supplied.

The data is reviewed for completeness. Surface Draft A draft analysis is completed for all class ‘A’ components using the grain / draft information

supplied on the Project APQP Plan Form 3.3. Parting Lines The parting lines of the tool are reviewed to ensure the robustness and reliability of the tool

in the manufacturing environment. Any poor tooling conditions are to be documented and forwarded to the customer with proposals to eliminate the poor condition.

Ribs Ribs are reviewed to ensure that they will not cause cosmetic problems after the product is

manufactured. This is based on the type of material being used to manufacture the product. The material supplier or customer should supply guidelines for proper rib design.

The ribs are also checked for draft and thickness to ensure the ability to manufacture the

ribs in the tool using the EDM process. General Information The part is reviewed for proposals that would allow the elimination of unneeded complexity. Prior to submitting the proposals for product alteration, any mating part geometry is

reviewed if available. Signature and Distribution The associate assigned to the Tooling Feasibility Study Form 3.16 must sign it upon

completion. The form is then forwarded to the program manager. If the feasibility study is completed prior to receiving a Project APQP Plan 3.3, it is forwarded

to the party that requested the feasibility study.

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SALES AND PROGRAM MANAGEMENT (SECTION 3) 3.16 Tooling Feasibility Study Outcome Program management is responsible to coordinate with the customer to close out all

feasibility issues, all part deviations, and enhancements outlined in the Tooling Feasibility Form 3.16.

The Tooling Feasibility Study Form 3.16 and all attachments will be maintained in the master

engineering job folder. RELATED DOCUMENTATION Form – Project APQP Plan 3.3 Form – Tooling Feasibility Study 3.16 Procedure – Concept Phase Section 3.7 Procedure – Concept Phase Section 3.7 Procedure – Incoming Data & Naming Convention Section 9.1

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SALES AND PROGRAM MANAGEMENT (SECTION 3) 3.17 Customer Satisfaction PURPOSE To monitor customer satisfaction and dissatisfaction. SCOPE All recurring customers for Proper Group International. RESPONSIBILITY It is the responsibility of the director of Sales to ensure this procedure is followed. The corporate quality & development associate is responsible for maintaining the documents for customer satisfaction. PROCEDURE Within 60 days of a new customer’s first new tool T1, a Customer Survey Form 3.17 is

completed. The director of sales will complete the survey by gathering the feedback from the customer contact.

The customer contact must be a person from one of these areas: Purchasing Management Manufacturing/Engineering Processing

For all current customers, the director of sales is to review the Customer Survey Form 3.17

on a yearly basis with the customer contact. This must take place between September and December.

If action needs to be taken it is also noted on the backside of the form along with a due date. The director of sales forwards this information to the responsible associate and follows up to

ensure the action is complete. When all the information and follow-up information (if any) is satisfactory, the Customer

Survey Form 3.17 is forwarded to the executive administrative associate with all the pertinent information listed on this form.



Management 09/05/00 07/07/09 005

Rev: Changed to director of sales & corp quality. Will do within 60 days of new tool T1

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SALES AND PROGRAM MANAGEMENT (SECTION 3) 3.17 Customer Satisfaction (continued) Key information from the survey is then accumulated onto the Customer Survey Summary

3.17a. After completion of all surveys, the Customer Survey Summary Form 3.17a is completely

filled out and given to the Officers of the Company and the general managers. RELATED DOCUMENTATION Form – Customer Survey 3.17 Form – Customer Survey Summary 3.17a Procedure – Management Review Meeting of the Quality System Section 2.1 Level 1 – Management Review – General Section 5.6.1 Level 1 – Customer Satisfaction Section 8.2.1 Level 1 – Corrective Action Section 8.5.2

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SALES AND PROGRAM MANAGEMENT (SECTION 3) 3.18 Corrective Action Reporting & Response PURPOSE A system is maintained to identify any customer complaints regarding completed and finished tooling and a process to describe to document the response. SCOPE The procedure describes the customer complaint and issues corrective action to resolve complaint / nonconformity. RESPONSIBILITY The sales department and/or program management and/or corporate quality & development has the responsibility to document and initiate corrective action. PROCEDURE If Proper Group International receives verbal or written information or a complaint regarding a mold as currently complete or in production, the following procedure is followed: The sales associate or program manager will complete the following: investigates areas of concern such as dimensional, accuracy’s and/or cosmetic

conditions of the product initiates receipt of the mold or plant support as required prepare a Change Order Form 3.15 / 3.15.5 outlining all corrective actions required to

satisfy the customer and to document the customer’s concerns or complaints. discuss corrective action with the manufacturing supervisor/manager and the mold

leader regarding what corrective actions are necessary and what corrections will be implemented.

If the customer complaint or concern cannot be addressed by a change order and does not

meet the criteria for an 8D, a Corrective Action Request Form 2.2b will be requested by the internal audit team. (Reference Procedure – Internal Quality Audit Section 2.2)

If the program manager/concerned associate or manufacturing supervisor/manager deems it

necessary to do an 8D Concern Analysis Report Form 3.19 due to similarities of other conditions, an 8D is completed. (Reference Procedure – 8-Discipline Problem Solving Method Section 3.19)



Management 09/05/00 03/06/09 003

Rev: can use a CAR for customer complaints if necessary

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SALES AND PROGRAM MANAGEMENT (SECTION 3) 3.18 Corrective Action Reporting & Response (continued) All corrective actions that require a follow-up are recorded on the Corrective Action Calendar

in Outlook to ensure follow-up does occur in a timely manner. This calendar is maintained by the corporate quality & development associate.

RELATED DOCUMENTATION Form – Corrective Action Request 2.2b Form – Change Order 3.15 Form – Change Order 3.15.5 Form – 8D Concern Analysis Report 3.19 Procedure – Internal Quality Audit Section 2.2 Procedure – 8D Problem Solving Method Section 3.19 Level 1 – Customer Communication Section 7.2.3 Level 1 – Customer Satisfaction Section 8.2.1 Level 1 – Corrective Action Section 8.5.2 Reference – Corrective Action Calendar

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SALES AND PROGRAM MANAGEMENT (SECTION 3) 3.19 8-Discipline Problem Solving Method PURPOSE The 8-Disciplines Problem Solving Method or “8-D’s” is to be used in all cases where a problem, both internal and external, cannot be solved simply. SCOPE Applies to all molds/tools and related product manufactured by Proper Group International. RESPONSIBILTY It is the responsibility of the corporate quality & development department or quality manager to document any actual or potential nonconformance. PROCEDURE At the discretion of the quality manager or management team member’s authorization, an

8D Concern Analysis Report Form 3.19 will be implemented and processed. An 8D Report Number is requested from corporate quality & development.

The 8D is recorded on the 8D Matrix Form 3.19a with the 8D Report Number, the Customer, and the Program by corporate quality & development.

A team will be formed and the concern documented on the 8D Concern Analysis Report

Form 3.19. Proper Group International - After the initial meeting with the team members, a copy will

be returned to the corporate quality and development department for documenting. The progress completion and results of each 8D performed will be reviewed in the weekly project scheduling meeting.

Sub-Suppliers – After the initial meeting with the team members, a copy will be returned to

the Proper Group International purchasing department and the corporate quality and development department for documenting. The progress completion and results of each 8D performed will be revised in the weekly project scheduling meeting.

The 8D Concern Analysis Report Form 3.19 information will be updated on the 8D Matrix

Form 3.19a. The Due Date will be recorded and monitored by corporate quality & development.

Upon completion of steps D1 – D8 listed below, the 8D will be closed. The following will

occur: The final document will be forwarded to corporate quality & development for completion

and for saving onto the network. The 8D Matrix Form 3.19a will be updated.



Management 09/05/00 03/06/09 006

Rev: monitoring & closing of an 8D has been added, CA Calendar has been added

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SALES AND PROGRAM MANAGEMENT (SECTION 3) 3.19 8-Discipline Problem Solving Method (continued)

Listed below are steps D1 – D8. D1. FORM THE TEAM - In this first step, a group of people will be given time and authority to

solve the problem and implement corrective actions. This group should have a designated team leader.

D2. DESCRIBE THE PROBLEM (OBJECT, CONCERN, QUALIFICATION) - The internal /

external customer problem must be stated in specific, quantifiable terms. D3. IMPLEMENT AND VERIFY INTERIM CONTAINMENT ACTIONS – Define and implement

containment actions to isolate the effect of the problem from any internal / external customer until corrective action is implemented and verified.

D4. FIND AND VERIFY ROOT CAUSE - Identify all potential causes which could explain why

the problem occurred. Isolate and verify the root cause by testing each potential cause against the problem description and data. Identify alternative corrective actions to eliminate root cause.

D5. SELECT CORRECTIVE ACTIONS AND VERIFY - Test programs quantitatively and

confirm the selected corrective actions will resolve the problem for the customer and will not cause undesirable side effects.

D6. PERMANENT CORRECTIVE ACTIONS - Define and implement the best permanent

corrective actions. Choose on-going controls to insure the root cause is eliminated. Monitor the long term effects and implement contingency actions if necessary.

D7. ACTIONS TO PREVENT RECURRENCE OF THE PROBLEMS - Modify the management

systems, operating systems, practices and procedures to prevent recurrence of this and all similar problems.

D8. CONGRATULATE THE TEAM - Recognize the collective efforts of the team. If an 8D Concern Analysis Report Form 3.19 is not turned into to corporate quality &

development by the due date, the person who was issued the 8D Report Number is contacted for an update.

If more time is needed and this is approved by a managing associate, the Due Date is revised and documented on the 8D Concern Analysis Report Form 3.19 and the 8D Matrix Form 3.19a.

If this is not the case, the 8D Concern Analysis Report Form 3.19 must be turned in by the

close of business the following day.

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If the 8D Concern Analysis Report Form 3.19 is not received, the associate’s immediate supervisor is contacted.

The 8D must close within 7 business days or it will be given to the President.

3.19 8-Discipline Problem Solving Method All 8Ds are also recorded on the Corrective Action Calendar in Outlook to ensure follow-up

does occur in a timely manner. This calendar is maintained by the corporate quality & development associate.

RELATED DOCUMENTATION Form – 8D Concern Analysis Report 3.19 Form – 8D Matrix 3.19a Procedure – Management Review Meeting of the Quality System Section 2.4 Procedure – Project Scheduling Meeting Section 3.13 Procedure – Corrective Action Reporting & Response Section 3.18 Level 1 – Corrective Action Section 8.5.2 Level 1 – Preventive Action Section 8.5.3 Reference – Corrective Action Calendar

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SALES AND PROGRAM MANAGEMENT (SECTION 3) 3.20 Action Plans PURPOSE To standardize the procedure for implementation of project action plans. SCOPE This procedure applies to select production and prototype molds produced by Proper Group International. RESPONSIBILITY It is the responsibility of the scheduling department to facilitate the meeting. All the department leaders and program managers have the responsibility to recommend molds as candidates for this procedure. PROCEDURE When a program manager or department leader identifies a mold which is behind the

established timeline to the point that recovery utilizing the existing plan is not possible, an action plan meeting is initiated at the discretion of scheduling department.

The meeting will consist of a cross functional team including all affected department leaders. The team consists of some or all of the following associates: General Manager of Manufacturing Program Manager Scheduling Manufacturing Supervisor or Department Leader Core Manufacturing

During the Action Plan meeting, the team will discuss how to get the job back on track, what

resources to use, and the option of needing to outsource. Upon completion of the meeting, the scheduling department will update the new timeline. RELATED DOCUMENTATION Level 1 – Corrective Action Section 8.5.2



Management 09/05/01 01/14/09 005

Rev: Updated team members, omitted Form 3.20

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SALES AND PROGRAM MANAGEMENT (SECTION 3) 3.21 Tryout Scheduling / Pre Sampling Phase PURPOSE This procedure is a guideline for scheduling tryouts, define objectives, verify all materials necessary for initial mold sampling is present, and tracking tryout costs against jobs. SCOPE This procedure applies to Proper Tooling. RESPONSIBILITY It is the responsibility of program management and the process engineering departments for adherence to this procedure. PROCEDURE This procedure encompasses both in house and outsourced tryouts. To initiate a tryout, the program manager first completes a Request for Tryout Form 3.21.

This form must include the following information: Sequential Request for Tryout Form Number Location, Time, and Date Quote Number (for chargeable tryouts) Quantity of Parts Press Sizes Purpose of Tryout Tryout Material Information Packaging Information Quality Inspections Required Special Equipment & Mold Features

In addition, if the tryout is to be run outside Proper, the program manager must obtain

purchase order coverage and follow the Receipt of Purchase Order Procedure 3.4. NOTE: This includes tryouts run at Proper Polymers – Anderson / Croswell or at any

other outside source. To ensure proper tracking of tryouts, a copy of the Request for Tryout Form 3.21 must be

forwarded to the administrative associate of program management. The administrative associate will enter the tryout information including any applicable sales

amounts into Proper’s accounting system. The tryout information is then filed in the master job file.



Management 03/26/01 02/01/09 007

Rev: Combined procedure 3.9 with 3.21.

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SALES AND PROGRAM MANAGEMENT (SECTION 3) 3.21 Tryout Scheduling (continued) A copy of the Request for Tryout Form 3.21 is forwarded to the tryout department. The

tryout department will: Retrieve and store the raw materials from Proper’s material warehouse (See Tryout

Material Handling Procedure 3.22). Track the tryout schedule. Get the appropriate equipment ready for the tryout.

Upon completion of the tryout, the form is filed in the process engineering master files with a

copy of the Open Issues Action Plan Form 3.6, and the processing information from the injection molding machine and Set Up / Process Sheet for T1 Form 3.21a.

See Tryout Instructions Section 3.23 of the Proper Procedure Manual for further guidelines

on tryouts. The press schedule for in house and outside tryouts is located in the f:\admin\project directory\press schedule\press schedule.doc

The Request For Tryout Form 3.21 is distributed to the following associates: Quality Process Engineer Mold Leader General Manager Manufacturing Program Manager Manufacturing Supervisor Scheduling Master Job File

RELATED DOCUMENTATION Form – Open Issues Action Plan 3.6 Form – Request For Tryout 3.21 Form – Set Up / Process Sheet for T1 3.21a Procedure – Receipt of Purchase Order Section 3.4 Procedure – Tryout Material Handling Section 3.22 Procedure – Tryout Instructions Section 3.23 Level 1 – Planning of Product Realization Section 7.1

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SALES AND PROGRAM MANAGEMENT (SECTION 3) 3.22 Tryout Material Handling PURPOSE This procedure is a guideline by which Proper Tooling’s shipping & receiving department will manage tryout materials inventory and track material usage and location. SCOPE This procedure applies to Proper Tooling. RESPONSIBILITY It is the responsibility of the shipping & receiving department and the process engineering department for adherence to this procedure. PROCEDURE All plastic resin and other tryout materials are to be received through the shipping &

receiving department located at the Proper Tooling. Upon receipt of tryout materials, the shipping & receiving department will create a Product

Identification tag including the following information: Job Number Resin Type & Color Date Received Storage Location Quantity Received

A copy of the tag is attached to the raw material. The raw material is then stored at the

Proper Tooling facility. The material is also logged in the Materials Inventory spreadsheet. Upon tryout completion, the Product Identification tag is filled out by the process engineer

with the date, location of the tryout, quantity of material remaining and any other additional comments or notes and re-attaches it to the material.

Upon final shipment of the mold to the customer, the shipping & receiving department is to

check the Materials Inventory spreadsheet and return any remaining raw materials to the customer with the mold.

Once the materials are returned to the customer, it is removed form the Materials inventory

spreadsheet.



Management 03/26/01 12/15/08 003

Rev: Changed company name & logo

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SALES AND PROGRAM MANAGEMENT (SECTION 3) 3.22 Tryout Material Handling RELATED DOCUMENTATION Form – Request for Shipment / Tryout 5.1 Procedure – Tryout Scheduling Section 3.21 Procedure – Tryout Instructions Section 3.23 Reference – Materials Inventory Tag – Product Identification

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SALES AND PROGRAM MANAGEMENT (SECTION 3) 3.23 Tryout Instructions PURPOSE This procedure provides specific instructions for execution of tryouts at the Proper Tooling. SCOPE This procedure applies to Proper Tooling RESPONSIBILITY It is the responsibility of the process engineering department and program manager for adherence to this procedure. PROCEDURE Upon receipt of the Request For Tryout Form 3.21, the process engineering supervisor

schedules the tryout. (See Tryout Scheduling Section 3.21 of the Proper Group International Procedures Manual for information on scheduling tryouts).

The Request For Tryout Form 3.21 is placed on the tryout scheduling board in the

designated slot accompanied by the following information: Processing Information from Injection Molding Machine if available Open Issues Action Plan Form 3.6 for repeat tryouts

During the tryout, the program manager and process engineer will complete their

appropriate areas of the Mold Performance Evaluation Form 12.4c and Part Performance Evaluation Form 12.4d.

Any open issues from these will transfer to the Open Issues Action Plan Form 3.6. The

program manager will enter any additional tryout open issues directly on Form 3.6.

Immediately upon completion of the tryout, the following steps are followed (prior to running the next tryout):

The mold is removed from the press and the process technician is to move the mold to

the die cart area. The raw material is re-weighed and the remaining weight is written on the Product

Identification tag. Any scrap parts from the tryout are discarded outside.



Management 03/26/01 02/01/09 004

Rev: updated with new APQP information that is required.

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SALES AND PROGRAM MANAGEMENT (SECTION 3) 3.23 Tryout Instructions (continued) The area around the press is then completely cleaned.

The Mold Performance Evaluation Form 12.4 is filled out and forwarded to the

administrative associate, for first tryout only unless otherwise requested. A copy is filed in the process engineer’s master job file.

The Request For Tryout Form 3.21, Open Issues Action Plan Form 3.6, and the

processing information from the injection molding machines are filed in the process engineering master job file.

The Project Overview Form 3.11 is updated with the date of the tryout. RELATED DOCUMENTATION Form – Open Issues Action Plan 3.6 Form – Project Overview Form 3.11 Form – Request For Tryout 3.21 Form – Mold Tryout Open Issues 12.3 Form – Mold Performance Evaluation 12.4 Form – Mold Performance Evaluation 12.4c Form – Part Performance Evaluation 12.4d Procedure – Tryout Scheduling Section 3.21 Procedure – Tryout Material Handling Section 3.22 Procedure – Mold Tryout Open Issues Section 12.3 Procedure – Mold Performance 12.4 Level 1 – Control of Production and Service Provision Section 7.5.1 Tag – Product Identification

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SALES AND PROGRAM MANAGEMENT (SECTION 3) 3.25 Engineering Change Worksheet PURPOSE This procedure is to review potential engineering changes to molds under construction or complete. The review process is to consider correct data levels and impact on the mold. SCOPE Applies to all production molds / tools that are currently active. RESPONSIBILITY It is the responsibility of the core manufacturing group and program management to adhere to this procedure. PROCEDURE Whenever new data is received for an active job and requires action to be taken and had the

surface model released, an overlay will be performed by the core manufacturing group or program management.

The core manufacturing data support associate or program management data support

associate must complete the Engineering Change Worksheet Form 3.25 during the overlay process.

The Engineering Change Worksheet Form 3.25 will be marked to indicate the impact on the

job for each item on the checklist. In the “Additional Comments” section, it is noted as to what the revision is for each area

effected. After the associate has evaluated the effect to the tooling, the associate will estimate the

time required for each step of the change and enter the days estimated on page two of the worksheet.

The associate then completes the Engineering Change Worksheet Form 3.25, and signs

page two. The overlay and the Engineering Change Worksheet Form 3.25 are then forwarded to the

associate supervisor of process planning for approval. The original Engineering Change Worksheet Form 3.25 and overlays are then forwarded to

the program manager to complete the quote to the customer. A copy of the Engineering Change Worksheet Form 3.25 and overlays are maintained in the

core manufacturing records.



Management 08/09/06 01/19/09 004

Rev: Removed production related information on page 2.

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SALES AND PROGRAM MANAGEMENT (SECTION 3) 3.25 Engineering Change Worksheet If the customer authorizes the quoted change, the overlays and the Engineering Change

Worksheet Form 3.25 will be attached and distributed with the Change Order Form 3.15. RELATED DOCUMENTATION Form – Change Order 3.15 Form – Engineering Change Worksheet 3.25 Level 1 – Planning of Product Realization Section 7.1 Level 1 – Control of Design and Development Changes Section 7.3.7

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QUALITY (Section 4) 4.1 Control of Measuring & Test Equipment PURPOSE This procedure provides specific instructions for the verifications, calibrations and the maintenance of measuring and testing equipment to ensure proper functioning and continued accuracy, thus ensuring that molds/tools/components adhere to prescribed design requirements. SCOPE This applies to all measuring equipment, mechanical and electric, used by associates for final verification of part and product acceptability. RESPONSIBILITY The quality department has the overall responsibility to ensure these procedures are being followed. PROCEDURE

Hand measuring equipment/tools, company and associate owned within the quality department. There are two sections:

Large or high accuracy measuring equipment, needing an outside calibration source. The quality department will maintain records on all equipment that is listed in the two sections. These

records will include calibration dates and calibration procedures. The quality department is responsible for identifying and calibrating all inspection, measuring, or test

equipment that verifies the quality of the end product.

Calibration – an in house equipment verification to the standards established within this procedure.

The levels of calibration are:

Calibration with a Certificate – a verification of the accuracy of equipment conducted by an outside accredited source as outlined within this procedure.

The quality department will identify the level of calibration each piece of equipment will require. The quality department will also maintain a “Set Of Standards” that all measurable equipment will be

calibrated to.

The temperature and humidity of the quality department calibration area is controlled and monitored through the use of a certified hygrometer / thermometer and recorded to facilitate proper performance of calibration / verificatio


Established Revision Rev # Quality 09/05/00 03/20/09 008

Rev: Added criteria - suitable environmental conditions & the procedure for control/maintaining

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QUALITY (Section 4) 4.1 Control of Measuring & Test Equipment Environment:

Temperature: 68 +/- 1 degree F (20+/- .56 degrees C) Humidity: (RH) of 50% max

Non quality department manufacturing associates trained on the use of measuring equipment may periodically test their own tools or company tools. These will not be recorded on the Proper master list. This equipment is considered for reference only.

“Certification Tags” Each piece of equipment / hand tool in the quality department is tagged. The tagging system will consist of the following:

“In Calibration” Identification Tags – labels or tie on tags. This tag will be used as the “In Calibration Tag”.

“Third Party Certification”

Tags placed on equipment / tools calibrated by an outside source. “Reference Only”

Tags are placed on equipment / hand tools. These tools are not to be used for final inspection.

Any piece of equipment can be used for final inspection as long as it has:

An Identification Tag / In Calibration Tag The next calibration due date has not passed.

Any piece of equipment / hand tool outside of the quality department that does not have a certification

tag is to be considered “Reference Only.” This is for both company owned and associate owned tools.

Any measuring and test equipment that is out of calibration is taken out of service. The out of

calibration equipment will need to be sent out for repair or recalibrated before it can be used. These information tags will contain the following information as a minimum:

the next calibration due date the serial number assigned to that tool.

The inspection, measuring and test equipment records will be maintained through the use of a

software program. received condition for in-house calibrations will be input into the software. finished condition for in-house calibrations will also be input into the software.

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QUALITY (Section 4) 4.1 Control of Measuring & Test Equipment Calibration frequencies and tolerances are established based on past experience with the equipment,

manufacturers’ recommendations and the critical nature of the inspection, measurement, or test being performed.

The quality department will maintain all masters used to calibrate any equipment listed in any of these

sections. All masters must be kept in the quality department and not removed without permission of the quality

manager. All masters used to calibrate the above listed equipment will be calibrated with a certificate from an

outside source. A master list of all equipment needing calibration will be kept in the quality room and will need to be

updated once a month. This is due to the possibility of new equipment being put into place. Hand Measuring Equipment / Tools – company and associate owned The following company and associate owned equipment / tools within the quality department are

controlled by this procedure.

depth micrometers outside micrometers calipers indicators height gages

There will be label tags placed on every piece of company owned and associates personal equipment

/ tools within the quality department. Each tagged piece of equipment / tool will have its own unique serial number. All equipment used for final verification will be recorded and tracked as required per our software

program. The quality department will conduct all calibrations of equipment listed above. Frequency of calibration for the above will be as follows:

Every six months

NOTE: Some tools will require the tags to be removed for use. Tags to be replaced upon completion of use.

All general procedures apply.

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QUALITY (Section 4) 4.1 Control of Measuring & Test Equipment All final inspection equipment is under the control of the quality control department. Large or High Accuracy Measuring Equipment – needing an outside calibration source The following is a list of equipment needing outside calibration.

Coordinate Measuring Machine (CMM) Gage Blocks

Frequency of calibration will be as follows:

every eighteen months all coordinate measuring machines (CMM)

every three years gage blocks

All outside calibration sources provide a certificate of calibration once complete. All of the above equipment is tagged showing when it was calibrated and when the next calibration is

due. Any equipment not meeting the specifications is tagged and service is completed to bring the

equipment back in calibration. All new equipment in the quality department must be recorded and entered into the software program. All general procedures apply. Out of Calibration Hand Tools & High Accuracy Measuring Equipment The quality supervisor will review any item found out of calibration to see if it is out of tolerance by

over .001” and/or evaluate the possible effect on any in process checks and past checks that were performed.

If items are found to have an effect, they are listed on the Out Of Calibration Checklist Form 4.1. The Out Of Calibration Checklist Form 4.1 is then reviewed with the general manager. The general manager will determine if there is a probability of suspect material / items in process or

shipped. If yes, the customer will be notified and consulted with any corrective actions that may need to be

taken.

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QUALITY (Section 4) 4.1 Control of Measuring & Test Equipment RELATED DOCUMENTATION Form – Out Of Calibration Checklist 4.1 Procedure – Control of Machine Controllers & Test Equipment 4.3 Level 1 – Planning of Product Realization Section 7.1 Level 1- Control of Monitoring and Measuring Devices 7.6 Reference – Measurement Systems Analysis Manual

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QUALITY (Section 4) 4.2 General Tooling Tolerances & Specifications PURPOSE To establish standard mold construction tolerances for certifying molds constructed by Proper Group International in the event the customer does not supply. SCOPE Applies to all production molds only. RESPONSIBILITY The quality department has the overall responsibility to ensure these procedures are followed. PROCEDURE In order to maintain tooling deliveries and establish reasonable dimensional standards and

practices for tooling construction, Proper Group International will utilize the following tooling tolerances and specifications to construct new tooling/perform engineering changes unless provided with the following:

A complete GD&T part print provided no later than two weeks after tool kick off.

Immediately required for engineering changes. A set of tolerances is agreed upon and provided in letter form no later than two weeks

after tool kickoff. Immediately required for engineering changes. In the event a GD&T part print is supplied after the required date, Proper Group International

will need to review the information supplied and determine what can be incorporated into the tool build schedule without affecting delivery.

NOTE: Items controlled by First Article Inspection – all tolerances per customer specifications.

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QUALITY (Section 4) 4.2 General Tooling Tolerances & Specifications

Feature Plus or Minus Callout

GD & T Callout

HOLES Size +/- .15 ∅ XX.XX +/- .15

*Location +/- .15 ⊕ 0.15 A B C

SLOTS

Size Length +/- .3 Width +/- .15

*Location Length +/- .15 ∅ XX.XX +/- .15 X XX.X +/- .25

Width +/- .15 ⊕ 0.15 A B C

HEAT STAKE HOLES Size + .15 / - .0 ∅ XX.XX +.15/-.0

*Location +/- .15 ⊕ 0.15 A B C

HEAT STAKES Size +.0 / -.15 ∅ XX.XX +.0/-.15

*Location +/-.15 ⊕ 0.15 A B C

CLIP ATTACHMENT RIBS

Size +/-.15 MAXIMUM THICKNESS: 50% OF WALLSTOCK *Location +/-.15 ⊕ 0.15 A B C

TRIMLINES and CONTOUR SURFACES +/-.25 0.50 A B C All trimlines and surfaces must not exceed a rate of 0.20

change of .20mm in a distance of 100mm.

DOGHOUSE BOTTOM SURFACES +/-.20 0.40 A B C Not to exceed a rate of change of .20mm over a 0.20

distance of 50mm.

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QUALITY (Section 4) 4.2 General Tooling Tolerances & Specifications

WALLSTOCK +/-.20 0.40 A B C

RADII +/-.25 0.50 A B C

ANGULARITY +/- 1° ⊃ 0.10° A B C

* Locations of Off Angle Features creating slides, lifters, core pulls, etc., the tolerance will be increased by +/- .15

OPTICAL TOOL SURFACE TOLERANCE SIGNAL LIGHTING DIMENSIONS +/- .10 mm ANGLES +/- .20 mm EDGE RADII 0.26 mm FORWARD LIGHTING

DIMENSIONS +/- .05 mm ANGLES +/- .2 mm EDGE RADII 0.125 mm

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QUALITY (Section 4) 4.2 Tooling Tolerances & Specifications

GENERAL PLASTIC PART TOLERANCE TABLE TOLERANCE FOR

THE LISTED MATERIAL

TOLERANCE FOR THE LISTED MATERIAL



LINEAR DIMENSION

EP, PF, PDAP, PESU, UP-BMC, PSU, PETP, ASA, ABS, PMMA, PPO, PA, PBTP, PPS, PS, PC, PVC-P, SAN, SB, PVC-U

EVA, UF,PETP, POM, VP, PP, PP/EPOM, CAB, CAP, SB, PAG, PA66, PA610, PA11, MF, CA, PA12, PE1

PB

0-3 +/-0.10 +/-0.18 +/-0.42 3-15 +/-0.16 +/-0.26 +/-0.54

15-30 +/-0.20 +/-0.34 +/-0.68 30-70 +/-0.30 +/-0.56 +/-1.00 70-120 +/-0.40 +/-0.82 +/-1.40

120-160 +/-0.48 +/-1.00 +/-1.70 160-200 +/-0.58 +/-1.30 +/-2.10 200-250 +/-0.70 +/-1.60 +/-2.50 250-315 +/-0.86 +/-2.00 +/-3.10 315-400 +/-1.06 +/-2.40 +/-3.80 400-500 +/-1.30 +/-3.00 +/-4.60 500-630 +/-1.60 +/-3.70 +/-5.80 630-800 +/-2.00 +/-4.70 +/-7.20 800-1000 +/-2.50 +/-5.80 +/-9.00

GENERAL NOTE:

The above tolerances do not apply for datum callouts. All dimensions shown are in mm.

RELATED DOCUMENTATION Level 1 – Design and Development Planning Section 7.3.1

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QUALITY (Section 4) 4.3 Control of Machine Controllers & Test Equipment PURPOSE This procedure provides specific instructions for the verifications, calibrations and the maintenance of machine controllers and testing equipment to ensure proper functioning and continued accuracy, thus ensuring that molds / tools adhere to prescribed design requirements. SCOPE This applies to all equipment, mechanical and electric, used by associates for final verification of part and product acceptability. RESPONSIBILITY The maintenance department has the overall responsibility to ensure this procedure is being followed. PROCEDURE The quality department will maintain the calibration records of machine controllers & test

equipment. The maintenance department is responsible for identifying and calibrating all machine

controllers that effect the quality of the end product. Machine Controllers & Test Equipment The following is a list of equipment that falls under this section: CNC EDM Machines CNC Milling Machines Equipment used to produce a final product that is dependent on a controller or software. Presetters

Calibration can be conducted in house using the ball bar method. Calibration procedures

will be followed as outlined in the software program supplied with the ball bar. CNC Milling and Boring machines will be tested with a circular method and EDM machine will use a positional method.

Only properly trained associates conduct the ball bar calibration method. Calibration can also be conducted by an outside calibration source. All test equipment is calibrated as outlined in the operating instruction. Calibration of test equipment is done in-house or by an outside calibration source. The type

of calibration will determine who will conduct the calibration. Issuing Dept. Officer


Quality 10/01/06 01/19/08 002

Rev: Added Presetters and changed frequency of calibration to every 12 months.

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QUALITY (Section 4) 4.3 Control of Machine Controllers & Test Equipment Calibration will be tagged indicating the next due date. Depending on how far out of tolerance the

machine is, it will receive a “for roughing only” (yellow) or “do not use out of calibration” (red). Frequency of Calibration Every 12 months All CNC milling, boring, & EDM machines The product manufactured determines calibration frequencies. Out of Calibration Machine Controllers & Test Equipment All items will be recorded in the software system with their received condition.

Machine calibration tolerances for machines are as follows:

Finish Machines .0015” Roughing Machines .0075” Boring Mills .003” EDM Machines .005”

If any of these items are found out of calibration they will be removed from the system, and

recalibrated before they are put back into the system. Items received out of calibration will be brought to the maintenance supervisor’s attention. The maintenance supervisor will review the item to see if it is out of tolerance by .0015” for finish cut,

and .003” for rough cut and/or evaluate the possible effect on any in process checks and past checks that were performed.

If items are found to have an effect, they are listed on the Out Of Calibration Checklist Form 4.1 The Out Of Calibration Checklist Form 4.1 is then reviewed with the director of engineering /

manufacturing. The director of engineering / manufacturing will determine if there is a probability of suspect material /

items in process or shipped. If yes, the customer will be notified and consulted with any corrective actions that may need to be

taken. RELATED DOCUMENTATION Form – Out Of Calibration Checklist 4.1 Procedure – Control of Measuring & Test Equipment 4.1 Level 1 – Planning of Product Realization Section 7.1 Level 1 – Control of Monitoring and Measuring Devices Section 7.6 Reference – Measurement Systems Analysis Manual

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SHIPPING AND RECEIVING (Section 5) 5.1 Shipping & Receiving Customer Molds/Tools/Components PURPOSE To establish a procedure for specifying and monitoring proper transportation activities and shipping practices to protect the quality of deliverable goods and to prevent their damage anywhere in the transportation and shipping process (includes customer supplied products). SCOPE Applies to all molds/tools/components manufactured by Proper Group International. RESPONSIBILTY It is the responsibility of the mold leader, program manager, and the shipping & receiving associate. PROCEDURE

General The shipping & receiving department will maintain all handling and transporting of incoming

and outgoing molds, tools, components, materials, etc. The shipping & receiving department will maintain a fleet of transportation vehicles to

support all products manufactured. The shipment of the mold/tool/component or related product is planned the most economical

way without sacrificing quality or safety. Shipment via Proper Logistics is desired. If they are not available outside subcontractors are to be used.

All molds shipped from a Proper Tooling facility are shipped FOB the Proper Group

International facility. All transportation costs are borne by the customer. All outgoing molds/tools/components will be packed in accordance with prescribed methods

and customer requirements, using materials designed to ensure that the product quality is maintained during transit. Order and product identification will be clearly marked and will provide for any contract or carrier requirements.

Upon the request to pick up molds/tools/components, the shipping & receiving associate will

schedule and arrange for pick up of the mold/tool.


Established Revision Rev # Shipping & Receiving

09/05/00 03/13/09 005

Rev: added details re: customer owned items and the process of tracking them. Added Section for Materials&Chemicals with a Specific Shelf Life. Mold lien picture is verified before shipment

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SHIPPING AND RECEIVING (Section 5) 5.1 Shipping & Receiving Customer Molds/Tools/Components (continued) Any incoming molds/tools/components scheduled by a third party and received by Proper

Group International must be verified that damages will not be attributed to the handling of Proper Group International. Any noticeable damage upon receipt must be documented on the transporter’s shipping documents.

Mold Shipment For Tryout All molds and tools that are completed and being shipped from our manufacturing facilities

to a tryout facility to perform a mold sampling will require the following forms: Request For Shipment Form 5.1 Mold Inspection For Tryout Form 12.2 Request For Tryout Form 3.21

Mold Shipment For Customer Plant Tryout Shipment of a mold to the customer’s facility Once a mold has been completed for shipment to the customer’s facility for a plant tryout,

the following forms must be completed by the program manager and submitted to the shipping & receiving department. Request For Shipment Form 5.1 Mold Inspection For Shipment Form 12.6

Once the shipping & receiving associate receives all documentation as listed above, they

will begin processing shipment of the mold. The shipping & receiving associate will then do the following: Create a shipper. Validate any outstanding purchase orders, the shipping & receiving associate will notify

a director, general manager or manufacturing supervisor for authorization to override. If authorization is given, the shipping & receiving associate will prepare the mold for

shipment. The shipping & receiving associate must validate that a picture of the mold with our

name & address engraved on it is stored on the f:\admin\mold-picture directory. If a picture is not found, the shipping & receiving associate must call the lien administrator to take the picture before the mold is prepared to ship.

NOTE: If after a successful plant tryout, the customer elects to keep the mold and consider the tool to be production ready, the following steps must be taken: The program manager must obtain a signed Customer Acceptance Form 12.7 from the

proper customer representative. The program manager will fill out and distribute the Request For Shipment Form 5.1 using

the Customer Acceptance approval date as the Final Shipment date.

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SHIPPING AND RECEIVING (Section 5)

It will be noted in the Additional Instructions section of the form, the actual date that the mold was shipped to the customer.

5.1 Shipping & Receiving Customer Molds/Tools/Components Mold Inspection For Final Shipment Final shipment of a mold to the customer’s facility Once a mold has been completed for final shipment to the customer’s facility, the following

forms must be completed by the program manager and submitted to the shipping & receiving department. Request For Shipment Form 5.1 Mold Inspection For Shipment Form 12.6 Customer Acceptance Form 12.7

Once the shipping & receiving associate receives all documentation as listed above, they will begin processing shipment of the mold.

The shipping & receiving associate will then do the following: create a shipper validate any outstanding purchase orders If shipment cannot be made due to outstanding purchase orders, the shipping &

receiving associate will notify a general manager or manufacturing supervisor/manager for authorization to override.

If authorization is given, the shipping & receiving associate will prepare the mold for shipment.

Final Shipment for Components Final shipment of a component to a customer’s facility

Once a component has been completed for final shipment to the customer’s facility, the

following forms must be completed by the program manager and submitted to the shipping & receiving department. Request For Shipment Form 5.1.5 First Article Certification Package (if required – reference Section 6.9)

Once the shipping & receiving associate receives all documentation as listed above, they

will begin processing shipment of the component.

The shipping & receiving associate will then do the following: verify that the components have a Quality Approval Stamp (reference Section 6.10) create a shipper validate any outstanding purchase orders

if shipment cannot be made due to outstanding purchase orders, the shipping & receiving associate will notify a general manager or manufacturing supervisor / manager for authorization to override.

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if authorization is given, the shipping & receiving associate will prepare the mold for shipment.

5.1 Shipping & Receiving Customer Molds/Tools/Components Receiving Customer Supplied Product Customer supplied product is very limited in the operation of Proper Group International. Typical customer supplied product encompasses plastic resin, packaging, gages, EOA

tooling, secondary equipment and mating components.

The program manager is notified when the customer’s property arrives. The program manager will give direction for the appropriate location to store the product.

If changes to the product are required, a Change Order Form 3.15 is completed and

distributed by the program manager.

Copies of the incoming shipper or bill of lading are forwarded to the program management administrative associate to file in the master job file.

If Proper Tooling receives customer supplied product, the article is identified with a Proper

Group International Job number and is distributed to the appropriate location for use. Customer Tools All incoming molds received at a Proper Group International facility must be inspected prior

to removal from the transport vehicle. Any damages noticeable must be documented on the transporter documents received.

The program manager is notified when the customer’s property arrives. The program


If changes to the product are required, a Change Order Form 3.15 is completed and distributed by the program manager.

Copies of the incoming shipper or bill of lading are forwarded to the program management

administrative associate to file in the master job file.

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SHIPPING AND RECEIVING (Section 5) 5.1 Shipping & Receiving Customer Molds/Tools/Components Components & Materials If the product received requires a material certification or MSDS, the Material Certs / MSDS

Form 5.1a is filled out.

If components are controlled by a First Article Inspection Section 6.9, the shipping & receiving department will insure the material specifications match the Work Order Router Form 3.8.5. If the specifications match, they will sign and complete the Work Order Router Form 3.8.5 and forward the material to the appropriate manufacturing department.

If a supplied product from one of our suppliers is defective, the Incoming / In Process

Components & Material Inspection & Non Conformity Guidelines Section 6.2 is then followed.

A high amount of returns of products from our customer or from our suppliers will result in an

audit of the facility supplying the product. Materials and Chemicals with a Specific Shelf Life

A label with the product name and received dated (added by shipping & receiving) will be

attached to the copy of the purchase order by purchasing and forwarded to shipping & receiving for all items used in the manufacturing of the product that have a specific shelf life / expiration date.

When product comes in without an expiration date listed on the container, shipping & receiving will add the received date to the label and attach it to the container.

The materials or chemicals are delivered to the appropriate department once they are

correctly labeled.

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SHIPPING AND RECEIVING (Section 5) 5.1 Shipping & Receiving Customer Molds/Tools/Components RELATED DOCUMENTATION Form – Work Order Router 3.8.5 Form – Change Order 3.15 Form – Request For Tryout 3.21 Form – Request For Shipment 5.1 Form – Request For Shipment 5.1.5 Form – Material Certs / MSDS 5.1a Form – Mold Inspection For Tryout 12.2 Form – Mold Inspection For Shipment 12.6 Form – Customer Acceptance 12.7 Procedure – Tryout Scheduling Section 3.21 Procedure – Tryout Material Handling Section 3.22 Procedure – Tryout Instructions Section 3.23 Procedure – Handling & Storage Section 5.2 Procedure – Incoming/ In Process Components & Material Inspection & Non Conformity Guidelines Section 6.2 Procedure – First Article Inspection 6.9 Procedure – Intermediate & Final Inspection 6.10 Level 1 – Verification of Purchased Product Section 7.4.3 Level 1 – Customer Property Section 7.5.4 Level 1 – Preservation of Product Section 7.5.5 Level 1 – Monitoring and Measurement of Product Section 8.2.4

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SHIPPING AND RECEIVING (Section 5) 5.2 Handling & Storage PURPOSE To establish a procedure used to control and determine the quality of receiving incoming material, standard parts and supplies, in addition to controlling the same material in storage. SCOPE Applies to the inspection or acceptance of all incoming materials, raw material, standard parts and components. RESPONSIBILITY The responsibility for this control is assigned to the shipping and receiving department. PROCEDURE The shipping and receiving department is responsible for monitoring supplier’s compliance

to specifications designed to protect product quality. Material handling arrangements are made during all stages of manufacture, inspection and

test in order to prevent any risk to material quality. Proper works on an order as needed basis, a large inventory is not carried. A small stock of standard parts and small items used daily are kept and controlled by the

shipping and receiving department. The managing associate / associate supervisor of manufacturing approves the order of these items to replenish as needed.

When an order is received the shipping and receiving associate stores the purchased

components in the correct job staging area until required by the manufacturing associates. This procedure is only altered when shipment of large raw materials are required and are directed to the person or equipment needed for processing.

All material is checked by the shipping and receiving associate in terms of compliance to

specifications, completeness, transit damage, and proper and complete documentation. Materials received by Proper falls into three categories. Raw material, steel for molds/tools, resin, lubricants, adhesives, sealants, and coatings. Standard parts and accessories Tools required to manufacture the product


Established Revision Rev # Shipping & Receiving

09/05/00 03/13/09 003

Rev: Added guidelines for shelf life items.

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SHIPPING AND RECEIVING (Section 5) 5.2 Handling & Storage Material awaiting use or shipment will be identified and segregated in secure storage areas.

Suitable measures are taken to prevent damage or deterioration including a periodic inspection for materials condition.

The shipping and receiving department is responsible to conduct regular auditing of the

storage of goods to determine that products are maintained in a satisfactory condition and properly identified.

Rust preventive is used on all components in long term storage. Shelf Life When orders are placed for new chemicals, MSDS sheets and shelf life are obtained from

the vendor and added to the MSDS listing maintained on the Proper Group International network and at multiple locations within the manufacturing area at the Toolboss machine data screens.

A label with the product name and received date (added by shipping & receiving) will be attached to the copy of the purchase order by purchasing and forwarded to shipping & receiving for all items used in the manufacturing of the product that have a specific shelf life / expiration ate.

If a product comes in without an expiration date listed on the container, shipping & receiving

will add the received date to the label and attach it to the container.

The department supervisors will monitor the shelf life for any effected items within their department.

Every 3 months a copy of the chemical shelf life list will be sent to the following department

supervisors by the purchasing department to audit chemical shelf life in their area: Technologies Core Manufacturing 2D Machining Detail Department Benching Department Assembly Department

Any items past their recommended shelf life / expiration date will be discarded (appropriately).

The department supervisor will sign the sheet to record that the audit has been completed and any expired items have been properly disposed of within their area. This sheet is returned to the purchasing department where the records are maintained.

The purchasing department will summarize collected data to analyze these audits.

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The analysis will be prepared on a quarterly basis for review during the Quarterly Management Meetings. (Reference Procedure – Proper Group International Meetings Section 2.1).

5.2 Handling & Storage RELATED DOCUMENTATION Procedure – Proper Group International Meetings Section 2.1 Procedure – Shipping & Receiving Customer Molds / Tools / Components Section 5.1 Level 1 – Preservation of Product Section 7.5.5

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MANUFACTURING (Section 6) 6.1.5 In Process Verification PURPOSE This procedure establishes a method for verifying and controlling the quality of components throughout the manufacturing process. SCOPE This procedure is utilized throughout all the manufacturing departments on components controlled by a First Article Inspection Process (Section 6.9). RESPONSIBILITY It will be the responsibility of all associates to visually and physically verify each component as required by the Work Order Router Form 3.8.5. The verification should be documented on the Work Order Router Form 3.8.5 in the appropriate area for the completed operation and must be completed prior to release for the next operation. PROCEDURE Prior to performing any processes on items controlled by a First Article Inspection Procedure

6.9, the associate must have the Work Order Router Form 3.8.5. The router will provide direction for the process and the need for in-process verification.

Changes in processes are not allowed and must be completed per the Work Order Router Form 3.8.5 directions. If the process cannot be completed per the Work Order Router Form 3.8.5 instruction, quality, management, and manufacturing engineer must be notified. Product controlled by FAI will require recertification if changes are made.

Upon completion of a process that required verification, the associate must document the

results on the verification on the Work Order Router Form 3.8.5, also signing and dating to provide a record that the activity took place.

All products not meeting the verification will be corrected and re-verified before continuing to

the next stage of the process. Items that cannot be corrected by rerunning the process will be tagged with a red Non Conforming Tag and placed in the Non Conforming area. The number of items passing and failing will be identified on the Work Order Router Form 3.8.5 at each process interval.

The component can be moved to the next operation when the process is completed and the

verifications are complete and approved. Issuing Dept. Officer


Manufacturing 01/19/09 07/15/09 001

Rev: Added information re: changes to the Router and non conforming product procedure

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MANUFACTURING (Section 6) 6.1.5 In Process Verification Components that have been red tagged, entered into the Nonconforming Product Log Form

6.2 and placed in the Nonconforming Area. Manufacturing, engineering, and quality will evaluate all products in the Non Conforming

area to determine if a rework methodology meets the product specifications or the products are to be scrapped.

Once the rework of the nonconformity is complete, the component will be relabeled as OK to Process and moved onto the next operation. (See Procedure 6.2 – Incoming / In Process components & Material Inspection & Non Conformity Guidelines).

Items that are to be scrapped will be sawed in half or destroyed in a method that renders

them unusable. All previous in process stickers / labels / tags used to manufacture the subcomponents may

be removed at completion prior to an assembly operation. RELATED DOCUMENTATION Form – Work Order Router 3.8.5 Procedure – Incoming / In Process Components & Material Inspection & Non Conformity Guidelines Section 6.2 Procedure – First Article Inspection Section 6.9 Level 1 - Tag – Non Conforming Tag – Not Inspected Tag – OK To Process Tag – OK To Ship

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MANUFACTURING (Section 6) 6.2 Incoming / In Process Components & Material Inspection & Non Conformity Guidelines PURPOSE These procedures describe the system for management of mold/tool components and materials that deviate from specifications to determine disposition and analysis of that product. SCOPE This process applies to all incoming manufactured components, incoming purchased components, and incoming raw steel material. This process describes how to deal with incoming inspections and also nonconformities for the incoming and in process product. RESPONSIBILITY The responsibility of reporting and identifying a nonconformance is given to all associates. Associate supervisors have the authority to act on a nonconformance appropriate to the situation. PROCEDURE

Manufactured Components (Not Controlled by First Article Inspection) If a manufacturing associate discovers a nonconformance during the manufacturing of a

specific component or operation, the operation will shut down and the item will be yellow tagged immediately.

The manufacturing associate will notify the managing associate/associate supervisor of

manufacturing. After a review of the nonconformity, the supervisor along with the associate will decide on

the appropriate action. The actions are:

Remove and send for rework Rework will be documented be documented on the manufactured component or

through a Change Order Form 3.15 / 3.15.5. A yellow Not Inspected Tag will be attached to these components to indicate rework

is necessary and they will be sent back through various operations such as welding, machining, and benching operations

Modify Specifications It the component can be modified without compromising customer specifications,

verbal and/or written directions will be completed for modifications. Modification instructions may include engineering revision drawings and Change

Order Form 3.15 / 3.15.5. Issuing Dept. Officer


Manufacturing 09/05/00 07/07/09 006

Rev: Formatting issues on page 5

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MANUFACTURING (Section 6) 6.2 Incoming / In Process Components & Material Inspection & Non Conformity Guidelines

Manufacturing Components (Controlled by First Article Inspection – Section 6.9) If a manufacturing associate discovers a nonconformance during the manufacturing of a

specific component or operation, the operation will shut down and the item will be yellow tagged immediately.

The manufacturing associate will notify the managing associate / associate supervisor of manufacturing.

After a review of the nonconformity, the supervisor, the quality representative and the

associate will decide on the appropriate action. The actions are:

Remove and send for rework Rework will be documented on the Work Order Router Form 3.8.5 detailing the

processes to be added or reran. The yellow tag will be removed by a quality representative after the rework is

completed. Rework can be rerunning of the same operation or adding an operation providing it

does not affect the part specifications or quality.

Replace (non-repairable) A non-repairable component will be tagged with a red Non Conforming Tag. The

tags must be filled out and the item will be sent to the nonconforming area.

Incoming Components Incoming components used in the manufacturing process are either from a subcontractor,

from a purchased supplier or returned from a customer as nonconforming (Aerospace Only) Depending on what category as listed above, the following procedures are followed: Incoming Subcontractor All custom manufactured components from subcontractors must be 100% inspected prior to

release for completion in the manufacturing phase. Custom manufacturing components include ejector box assemblies, hot manifold systems,

and small detail components.

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MANUFACTURING (Section 6) 6.2 Incoming / In Process Components & Material Inspection & Non Conformity Guidelines Upon completion of this inspection a green OK To Process Tag will be attached on the

component authorizing release for assembly. If the incoming verification cannot be completed at the time of receipt, a yellow tag must be

attached to the component, which will identify the component as Not Inspected. Components with the yellow tag must be verified prior to usage. If a nonconformity is found, the decision will be made with the manufacturing

supervisor/manager to return the product or to make the modification internally.

A red Non Conforming Tag must be attached until the corrections / modifications are made.

All costs and time will be back charged to the supplier company (Tooling Only). (Reference Procedure – Vendor Charge Back Section 8.5).

If a Non Conformity is found, the item will have a red Non Conforming Tag attached, filled

out, and sent to the nonconforming area (Aerospace Only). Purchased Components All incoming purchased components will be inspected for the correct catalog number,

amount, and any special instructions at the time of the order. Purchased components will not be inspected for dimensional specifications. These

specifications are to be certified prior to shipment to our facility. Any components delivered that did not meet the purchase order specifications will be tagged

as nonconforming and moved into the nonconformance area to await resolution. The supplier will be notified of the incorrect product and the product will be returned for the

correct item.

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PROCEDURES MANUAL

MANUFACTURING (Section 6)

Cavity & Core Die Block

Incoming Raw Steel

All incoming raw steel must have a material certification. If the material certification is not available at the time of receipt, it must be received within 6 weeks.

Steel blocks that are purchased by the customer do not require steel certification. The

customer will receive these at their facility when the steel is purchased. 6.2 Incoming / In Process Components & Material Inspection & Non Conformity Guidelines Incoming cavity and core die blocks must be hardness tested. The tested hardness must be noted on the copy of the Purchase Requisition Form 8.1 The job number, detail number and/or detail name is marked on the outside of the raw

material for identification. Steel Bar Stock Incoming steel bar stock must be identified with the proper color code at the ends of the bar. If a material is specified for a job versus a standard stock, the material will be identified for

the detail and job numbers. All short pieces removed off of the original bar stock must be identified by color or steel

nomenclature. Incoming Raw Materials – FAI Controlled Components All incoming raw materials will be verified per the Work Order Router Form 3.8.5. The

certifications if required will be reviewed to insure they meet the specifications or standards listed on the router.

The review will verify that the elements of the certification match the specification or standards.

If the review is approved, the certification numbers and required information is documented

on the Work Order Router Form 3.8.5.

If the verification fails, the product will be classified as Non Conforming and the procedure for Non Conforming Product will be followed.

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Yearly, a validation of the certification reports for incoming materials will take place.

The validation will be random and one piece from 10% of our supply base will be recertified.

If an issue arises, the supplier will be contacted to resolve the manner. The material will be classified as nonconforming and the procedure for Non Conforming Product will be followed.

The quality manager and the purchasing manager are to be notified immediately to

determine how the issue is to be resolved.

6.2 Incoming / In Process Components & Material Inspection & Non Conformity Guidelines

Nonconforming Product Returned From a Customer (Aerospace Only)

All returned nonconforming product will be red tagged and placed in the Nonconforming area. The materials will be evaluated as all other nonconforming.

Nonconformance Area (Aerospace Only) The nonconformance area is located next to the rear exit door in the Aerospace building. All

red nonconforming products awaiting disposition must be relocated into this area. All components in the Non Conforming area must be red tagged and entered in the Non

Conforming Product Log Form 6.2.

The manufacturing supervisor and the quality manager will review on a daily basis the Non Conforming Product Log Form 6.2 and evaluate all products in the Non Conforming area to determine one of the following options:

If a rework methodology that meets the product specifications exists. Rework of the nonconformity will require a Work Order Router Form 3.8.5 detailing

the manufacturing methods, verification and/or inspections processes that are to be completed.

The reworked components can only be relabeled as OK to Process by a quality representative after the reworked components pass verification or inspection.

If the products are to be scrapped, the red Non Conforming Tag will be noted “Scrap

Part.” Products to be scrapped will be reviewed on a weekly basis with the general

manager and then will be scrapped by sawing the piece in half or destroying in a method that rends them unusable.

A deviation is to be requested from the customer to vary the product specification.

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The vice president of Proper Aerospace and the quality manager will be notified. They will decide if a product deviation will be requested for the customer or if the other two options are to be chosen.

All product deviations will be documented in written form denoting the specification change.

The parts will have the red Non Conforming Tag removed when the deviation approval is obtained in writing.

The parts will then be identified per customer’s specifications for deviated parts.

6.2 Incoming / In Process Components & Material Inspection & Non Conformity Guidelines RELATED DOCUMENTATION Form – Work Order Router 3.8.5 Form – Change Order 3.15 Form – Change Order Aerospace 3.15.5 Form – Non Conforming Product 6.2 Form – Non Conforming Product Log 6.2.5a Form – Purchase Requisition 8.1 Procedure – Management Review Meeting Section 2.1 Procedure – Shipping & Receiving Customer Tools Section 5.1 Procedure – In Process Inspection Section 6.1 Procedure – In Process Verification Section 6.1.5 Level 1 – Verification of Purchased Product Section 7.4.3 Level 1 – Monitoring and Measurement of Product Section 8.2.4 Level 1 – Control of Nonconforming Product Section 8.3 Tag – Non Conforming Tag – Not Inspected Tag – OK To Process

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PROCEDURES MANUAL

ALL DEPARTMENTS (Section 7) 7.1 Record Retention and Control PURPOSE To establish a process to ensure the control of quality records generated to demonstrate compliance with the Proper Tooling’s Quality Management System and Procedures. SCOPE Applies to all records completed to demonstrate compliance with the Proper Group International’s Quality Management System and Procedures. RESPONSIBILITY Personnel responsible for the areas or activities where quality management records are generated and stored are responsible to assure they are handled in a way that complies with this procedure. PROCEDURE All records completed to demonstrate compliance with the Proper Group International’s Quality

Management System and Procedures are filed so they are easily retrievable when necessary. They are stored in a suitable environment to prevent damage, deterioration and prevent loss. Reference the Quality Records / Record Retention and Control Matrix contained on the following pages

of this procedure for additional information.

All records will be maintained for the minimum time frame.

No records will be stored beyond the maximum time frame. It is the decision of the responsible party to dispose of the documents between the minimum and maximum time frame.

Disposition of the records will be done on a semi-annual basis.

Reporting of the proposed disposition list will be presented at the quarterly management meeting by the

quality system manager.

Upon approval of the disposition at the meeting, the records will be delivered to a third party record disposition company for shredding within 30 days of the approval.

All records are available for review by customers and regulatory authorities in accordance with the

contract or regulatory requirements. 7.1 Record Retention and Control


Established Revision Rev # All Departments 09/05/00 07/15/09 006

Rev: Records are available for review in accordance with contract or regulatory requirements

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PROCEDURES MANUAL

ALL DEPARTMENTS (Section 7)

Record Location Retention Responsibility Min Max

Management Review Reports

Corporate Development Files

3 Years 5 Years Corporate Development

Annual Internal Audit Schedule



Internal Audit Results & Internal Audit Reports



Training Records Human Resources Files

As long as employed at

the PME Companies

3 Years after Termination

Human Resources & Supervisor

Calibration Records

Quality Files 10 Years 12 Years Quality

Mold Inspection Reports Quality Files 3 Years 4 Years Quality

Component Inspection Records Proper Aerospace 10 Years from Shipment

13 Years after

Shipment

Quality

8D Concern Analysis Reports & Matrix



Mold Designs & Surface Files Engineering & Data Management Proper Tooling

6 Years (if operating system is

supported)

9 Years Engineering & Data Management Department

Product Data & Surface Files Proper Aerospace 10 Years from Shipment

13 Years Engineering

Customer / Program Management Files

Proper Tooling 3 Years from Ship Date

5 Years after Ship Date

Sales Program Management

Customer / Program Management Files

Proper Aerospace 10 Years from Shipment

13 Years after

Shipment

Sales Program Management

Data Management Records Proper Tooling Proper Technologies

3 Years 5 Years Data Management

7.1 Record Retention and Control

Record Location Retention Responsibility Min Max

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PROCEDURES MANUAL

ALL DEPARTMENTS (Section 7) Purchasing Files & Purchase Requisitions

Proper Tooling 5 Years 7 Years Purchasing

Estimating Quotes & Packages

Proper Tooling 3 Years 4 Years Estimating

Proper Quality Management System Level 1 Policy Manual


Until Expires Until Expires Corporate Development

Proper Quality Management System Level 2 Policy Manual



Advanced Product Quality Planning & Control Plan AIAG Manual



Measurement System Analysis AIAG Manual



Statistical Process Control Manual AIAG Manual



Potential Failure Mode and Effects Analysis AIAG Manual



ISO 9000 AIAG Manual Corporate Development Files


Aerospace Standard Corporate Development Files


RELATED DOCUMENTATION Procedure – Customer Property Section 3.9 Level 1 – Control of Records Section 4.2.4 Level 1 – Quality Management System Planning Section 5.4.2 Level 1 – Planning of Product Realization Section 7.1

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PROCEDURES MANUAL

ALL DEPARTMENTS (Section 7) 7.2 Document Control PURPOSE This is a guideline for controlling documents and creating, revising, and distributing procedures and forms. SCOPE This procedure applies to all controlled documents and new or revised standards. RESPONSIBILITY The document control representative is responsible for determining which documents are to be controlled and for developing the system to ensure only the latest revisions are being used. Implementation of any new or revised procedure/forms are be approved by the department manager with the final approval two officers of the company. The department manager is responsible for the training and implementation of these procedures/forms. PROCEDURE An outline of a new or revised procedure/form is written by the associate or manager responsible for the

procedure/form and is forwarded to the document control representative. The outline is then forwarded to the document control representative where it is written in the correct

procedure/form format and checked for duplication or conflict with the current procedures/forms. The rough draft is then reviewed by the responsible manager. Once the manager approves the rough draft, a final draft of the procedure/form is typed up. The procedure/form is then forwarded to an officer of the company for review, any revisions and

approval. The procedure / form is returned to the document control representative for distribution. The Procedure Distribution Form 7.2 is filled out for the new or revised procedure/form. All Proper

Group International Procedure Manuals and all associates affected by this procedure/form are listed on the distribution form. The following actions take place once this form is completed:

7.2 Document Control


Established Revision Rev # All Departments 09/05/00 03/06/09 003

Rev: Added procedure effectiveness review

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ALL DEPARTMENTS (Section 7) The document control representative updates the Standards directory on the company network with

the updated procedure/form. An e-mail is sent to everyone letting them know of this update or addition and informing them to review the updated/additional procedure/form. The Standards directory is located on the company network for all associates that have access. This directory is maintained by the document control representative to ensure that the latest

revision is being used. All approved documents have a red “controlled copy” in the lower right corner. The original

document has the original officer’s signature on them and is filed. If the document is printed, the “controlled copy” will print in black. This defines that the document

is now "UNCONTROLLED”. This electronic database is maintained by the document control representative and is backed up

by the information technology department. The managing associate is responsible for distributing and explaining the new procedure/form to the

indicated associates. It is also the managing associate’s responsibility to make sure the procedure/form is implemented, everyone understands the procedure/form, and everyone is trained. Training Records will be kept (Reference Procedure – Training & Development Section 1.1).

Hard Copies – in the event there are controlled manuals, the following actions will take place. The document control representative forwards this procedure / form along with an updated Revision

Log and Table of Contents to each associate in charge of a Proper Group International Procedure Manual where it can then be placed in the manual.

If the new procedure / form replaces a previous procedure/form, it is indicated on the Procedure

Distribution Form 7.2 The Procedure Distribution Form 7.2 also indicates which forms become obsolete and must be

attached to this form and returned to the document control representative. It is also indicated on the Procedure Distribution Form 7.2 of the Proper Group International Procedure Manual that all files saved in other directories must be deleted. It is each associates responsibility to make sure this is done.

A Master Document Return List Form 7.2a is filled out recording all associates requested to send back the obsolete forms.

All obsolete documents must be returned to the document control representative to be destroyed. Once the obsolete documents are received, it is indicated on the Master Document Return List Form 7.2a that the document has been destroyed.

7.2 Document Control (continued) All changes to the procedures/forms are recorded as changes on the Revision Log of controlled

documents contained in the Appendix of this manual.

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ALL DEPARTMENTS (Section 7) Procedure Effectiveness

Procedures are reviewed to ensure they are up-to-date with what the company is doing.

If a procedure is not revised within a year, the internal audit team will flag the procedure to review to see

if it is still up-to-date. (Reference Procedure – Internal Quality Audit Section 2.2) RELATED DOCUMENTATION Appendix – Revision Log Form – Procedure Distribution 7.2 Form – Master Document Return List 7.2a Procedure – Training & Development Section 1.1 Procedure – Internal Quality Audit Section 2.2 Procedure – Incoming Data & Naming Convention Section 9.1 Level 1 – Control of Documents Section 4.2.3 Reference – Table of Contents

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PROCEDURES MANUAL PURCHASING (Section 8)

8.1 Purchasing Guidelines PURPOSE To document and control all purchases throughout the company. Purchase requisitions are used as a way to authorize purchases required for manufacturing and administrative functions. SCOPE This procedure encompasses all purchases made throughout Proper Group International. RESPONSIBILITY The purchasing department has overall responsibility for adherence to this procedure. Responsibility for manufacturing job, non-job & administration purchases are outlined in the purchasing & approval guidelines (Purchase Requisition Form 8.1). Any associate may fill out a requisition and request approval for such a purchase.

PROCEDURES Purchasing Guidelines - General

All purchase requisitions must be completed in ink. No pencil copies are accepted. All purchases made must be from an approved Purchase Requisition Form 8.1. This form is filled out

for the item required including the vendor name, charge to division, and the person requesting the purchased products. Time and material type purchases must also have an estimate of total cost and a “not to exceed” cost if appropriate.

Prior to submission to the purchasing department, the requisition must have the appropriate approved

management signature(s) as listed in the lower box of the Purchase Requisition Form 8.1. Sales tax, if applicable, should be listed on the Purchase Requisition Form 8.1. The purchasing

department is responsible for verifying if sales tax applies to the purchase. All equipment purchases and modifications must be approved by an Officer of the Company. A copy of

the approved equipment purchase order must be sent to the officers in charge of operations and finance. (use 90000 series purchase order numbers)

All purchases must be made from the approved vendor list. Purchases outside of the approved vendor

list are not authorized unless accompanied by a New Vendor Approval Form 8.1a signed by an Officer of the Company.


Established Revision Rev # Purchasing 09/05/00 08/07/10 007

Rev: Updated Job relates approval signatures, & job titles for approval, chged Form 8.1

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8.1 Purchasing Guidelines (continued) Any personal items purchased through the company must be approved by a general manager or an

Officer of the Company. Terms of repayment on personal purchases will be based on the following schedule: Work Related: 25% per week Non-Work Related: Personal purchases will not be allowed

Purchasing Guidelines - Manufacturing Manufacturing purchases fall under two (2) main categories; job related (ie: die blocks) and non-job

related (ie: cutting fluid). A Purchase Requisition Form 8.1 must be filled out completely for all manufacturing purchases.

The majority of job related purchases are made from a completed bill of material (B.O.M.), located on

the stock column drawing of the mold design. After the design leader approves and signs the B.O.M. the materials are ordered by the purchasing department.

Approval of job related purchases, not on the B.O.M., including outsourcing and subcontracting, shall be

based on the following: Three Person Approval Signatures

1. Department Leader / Program Manager 2. Assistant Plant Manager / Plant Manager / Director of Program Management (when deemed

necessary) 3. VP of Operations

Approval of non-job related manufacturing purchases shall be based on the following: If less than $3,000 VP of Operations If over $3,000 Officer of the Company

If purchases are to be expedited, the lower “initial for Expedited Pick Up or Delivery” on Purchase

Requisition Form 8.1 must be initialed by an associate supervisor/manager or the general manager of manufacturing.

Purchasing Guidelines - Administrative A Purchase Requisition Form 8.1 must be filled out completely for all administrative purchases. Approval of administrative purchases shall be based on the following: If less than $1,000 VP of Operations If over $1,000 Officer of the Company

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8.1 Purchasing Guidelines (continued) Purchasing Guidelines - Blanket In general, blanket purchase orders apply to administrative and non-job manufacturing purposes and is

typically used in recurring situations. For example: To purchase standard, recurring, fixed price items (ie: maintenance contracts and negotiated prices) To purchase standard, recurring services (ie: Federal Express and Newspaper Ads)

To establish a blanket purchase order number: completely fill out a Purchase Requisition Form 8.1,

indicate in the description section that it is a “blanket purchase order”, and indicate the time period to which the blanket PO applies (ie: purchases through 12/31/97)

For future purchases covered under an existing blanket PO #, you must fill out a Purchase Requisition

Form 8.1, check the blanket PO box and put the blanket PO # on the PO # line. The requisition must still be approved by the appropriate authorized associate.

Purchasing Guidelines - New Vendors All new vendor approvals must be completed in ink. No pencil copies are accepted. In order to add a new vendor to the approved vendor list, the New Vendor Approval Form 8.1a must be

completed in full by the associate requesting a new vendor. The New Vendor Approval Form 8.1a must then be approved and signed by an Officer of the Company along with a completed Purchase Requisition Form 8.1 before items can be purchased from that vendor. Manufacturing subcontractors will require a site visit and the Vendor Visit Checklist Form 8.2c completed prior to new vendor approval. (see Vendor Guidelines Section 8.2 of the Proper Group International Procedures Manual).

Service and repair vendors who perform work at a Proper Group International facility must provide PGI

with proof of work compensation and liability insurance. This insurance information should be attached to the new vendor approval form prior to submission for approval. (see Insurance Requirements for Vendors, Subcontractors, & Outside Parties below).

For further information regarding the Vendor Approval process, see Vendor Approval Guidelines Section

8.2 of the Proper Group International Procedures Manual.

Insurance Requirements For Vendors, Subcontractors & Outside Parties

General Coverage – Vendors / Subcontractors / Outside Parties shall provide, at its own expense, the kinds of insurance in the minimum amounts of coverage set forth in the insurance schedule below to cover all loss and liability for damages on account of bodily injury, including death resulting from, and injury to or destruction of property caused by or arising from any and all operations carried on or any and all work performed under the Agreement.

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8.1 Purchasing Guidelines (continued)

Workers Compensation Statutory Coverage. Including occupational disease, if and as required, in a separate act. Coverage

should also include an all-states endorsement and employer’s liability Coverage B. Minimum limit required: $500,000 / $500,000 / $500,000

Commercial General Liability Insurance Policy to include premises & operations, products – completed operations and blanket contractual

liability. (The contractual section of the coverage must cover the specific contractual agreement being entered into). Minimum limits required:

General Aggregate Limit

(Other than products completed operations) $ 1,000,000 Products – completed operations aggregate 1,000,000 Personal and advertising injury limit 1,000,000 Each occurrence limit 1,000,000

Automobile Liability To include owned, non-owned and hired vehicles. Minimum limits required:

Combined Single Limit

Bodily Injury $ 1,000,000 Property Damage 1,000,000

Also, Vendor / Subcontractor / Outside Parties shall comply with all applicable no-fault laws.

Umbrella Liability Coverage shall be provided in the amount of $3,000,000.

Proof of Coverage Vendor / Subcontractor / Outside Parties must furnish, not later than the time of signing of the

Agreement, property executed Certificates of Insurance and, if requested, shall furnish Proper Group International with copies of the policies with all endorsements prior to the commencement of any work hereunder, including a copy of the contractual insurance endorsement insurance performance of the Indemnity clause included in the Agreement.

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8.1 Purchasing Guidelines (continued) Subcontractors Insurance Coverage – if any of the work to be performed under the terms of the

Agreement is awarded to a subcontractor by the Vendor / Subcontractor / Outside Parties, such subcontractor shall meet the insurance requirements normally and reasonably obtained by such subcontractors.

RELATED DOCUMENTATION Form – Purchase Requisition Form 8.1 Form – New Vendor Approval 8.1a Procedure – Vendor Approval Guidelines Section 8.2 Procedure – Verification of Subcontracted Product Section 8.3 Procedure – Design Outsourcing Section 15.3 Level 1 – Purchasing Process Section 7.4.1 Level 1 – Purchasing Information Section 7.4.2

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8.2 Vendor Guidelines PURPOSE This procedure provides specific instructions for the content, initiation, updating, revision and maintenance of the approved supplier list. SCOPE This procedure encompasses all purchases made throughout Proper Group International. RESPONSIBILITY The purchasing department and accounting department have overall responsibility for adherence to this procedure. PROCEDURE The guidelines to request a new vendor approval are outlined in the Purchasing Guideline Section 8.1 of

the Proper Group International Manual. A Proper Group International associate visits manufacturing subcontractors or completes a phone

interview before they become an approved vendor. A Vendor Visit Checklist Form 8.2c is filled out. If the vendor is approved, a New Vendor Approval Form 8.1a is filled out. If the vendor is not approved, the Vendor Visit Checklist Form 8.2c is noted as to why and forwarded to

the purchasing department to be filed in the master vendor files. Once an Officer of the Company approves the New Vendor Approval Form 8.1a, the vendor is entered

into the system by the accounting department. A master vendor report is available to all Proper Group International associates.

All purchases must be made from the approved vendor list. Purchases outside of the approved vendor

list will not be authorized unless accompanied by a New Vendor Approval Form 8.1a signed by an Officer of the Company.

Vendors are removed from the master vendor report by the accounting department through the direction

of the quality manager and/or purchasing associate for the following quality considerations. This must be approved by a general manager or an Officer of the Company. An unacceptable quality performance rating cannot be resolved. An unsatisfactory survey, audit, unanswered corrective action request or specific quality problem(s)

cannot be resolved.



Rev: Supplier questionnaires are reviewed by a team to evaluate overall performance & any issues. Purchasing gathers data & analyzes data for management review on a quarterly basis

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8.2 Vendor Guidelines (continued) NOTE: See the Supplier Questionnaire section for details regarding subcontractor development

also. Vendors are removed from the list at the discretion of the purchasing associate for reasons other than

quality considerations. Annually in September, the accounting department reviews the master vendor report. If there is no

activity for two years, the accounting associate sends the purchasing associate a list of these vendors. The purchasing associate reviews the list and determines which vendors are to be removed. Deletion will be accomplished provided there is no Syteline System warning.

At the customer’s request, Proper Group International will purchase material and/or components from

their approved list of subcontractors.

All vendors must use customer approved special process sources when required. All vendors must flow down to their sub-suppliers all applicable requirements and specifications.

The purchasing documents contain data clearly describing the product ordered, including part name and

number, job number and any required specifications. All purchasing documents are reviewed and approved for adequacy of specified requirements prior to

the release of the document.

To assure that all specifications are defined, any of the following may be required: Part or mold designs, data or drawings. Testing requirements or results. Inspection requirements and critical characteristics. Instructions for any required record keeping or audit procedure.

When there is subcontracting required, a Request To Supplier Form 8.2b is filled out listing all pertinent

information (if required).

The vendor must notify Proper Group International and obtain approval, when required, in the event of the following: Non conforming product or procedure. Change in specification, product or procedure. Inability to meet delivery commitment.

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8.2 Vendor Guidelines (continued) Supplier Questionnaire To ensure the consistency of quality procedures, a questionnaire is sent to suppliers on a yearly basis

(in March) by the purchasing associate. The questionnaire is only sent to suppliers that have impact on the quality of a final product. This questionnaire includes requirements for vendors based on ISO 9000.

The purchasing associate sends the Supplier Questionnaire Form 8.2 to the vendor with a date that the

form is due back. ISO certified vendors are not required to fill out the survey. However, they must sign the survey, attach

a copy of their current certificate to the survey form and return to Proper Group International’s purchasing department.

Once the Supplier Questionnaire Form 8.2 is received, the purchasing associate reviews the completed

questionnaire and approves or disapproves the form. If the vendor scores below 50 or the purchasing associate disapproves the Supplier Questionnaire Form

8.2, the vendor is notified to discuss the reason for the low score and corrective action is determined. For manufacturing subcontractors, correction action may be to initiate a vendor visit.

The purchasing associate documents all comments/notes on the Supplier Questionnaire Form 8.2,

along with any corrective actions that might have taken place during the year.

The results are then entered on the Supplier Questionnaire Review Form 8.2a. The Supplier Questionnaire Form 8.2 and any associated documentation are reviewed by the quality,

manufacturing, and purchasing managers to evaluate the overall performance of the supplier.

Any actions that are deemed necessary are documented on the Supplier Questionnaire Form 8.2 and the purchasing manager is responsible to insure an 8D Concern Analysis Report Form 3.19 is issued to the supplier to address the issues.

The Supplier Questionnaire Form 8.2 and any associate documentation are filed alphabetically in the

purchasing department.

The Supplier Questionnaire Review Form 8.2a Supplier Development The purchasing department monitors ongoing performance of the subcontractor to meet minimum

requirements.

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8.2 Vendor Guidelines (continued) All printed purchase orders have the following notations on them:

Proper Group International expects 100% on time delivery with vendors working toward an

equivalent ISO 9000 program. By acceptance of this purchase order you as supplier agree that Proper or their customer have the right to verify at your facility that the products or materials meet specified requirements.

Delivery performance will be measured against this order date. Material certifications / SPC data, or

as specified by the purchase order must be provided with each shipment or new lot of material. Product will be refused if certification is not received with shipment or faxed beforehand to the attention of shipping and receiving.

Per ISO 9000 requirements, all quality records and related documents must be maintained and

accessible to Proper Group International and its customers. These notes are also sent to the vendors along with the Supplier Questionnaire Form 8.2 and returned

with an acknowledging signature. If the suppliers are not meeting Proper Group International’s requirements, the purchasing associate will

contact them regarding any and all issues and develop an action plan to resolve the issue. The purchasing associate will monitor and work with the vendors to improve their timing / quality. The

length of time to work the vendor will be at the purchasing associate’s discretion depending on individual situations.

The purchasing department will collect and summarize data for vendor and supplier development to

analyze that the company’s goals for On-Time Performance, Costs and percent AS or ISO certified suppliers are met.

These analysis are prepared for review during the Quarterly Management Meetings. (Reference

Procedure – Proper Group International Meetings Section 2.1).

On-Time Performance will be tracked and summarized monthly for critical components. Critical components for tooling are cavity and core blocks, manifolds and plates. Critical components for Aerospace are raw materials and processing. Information collected should be a percentage of on-time deliveries per month.

Budget vs. Actual Information on budget costs versus actual costs on closed jobs per month.

Supplier Development Percent of suppliers that are ISO / AS certified. This is collected once a year and will be reviewed during the management meeting.

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8.2 Vendor Guidelines (continued) RELATED DOCUMENTATION Form – 8D Concern Analysis Report 3.19 Form – Supplier Questionnaire 8.2 Form – Supplier Questionnaire Review 8.2a Form – Request To Supplier 8.2b Form – Vendor Visit Checklist 8.2c Procedure – Proper Group International Meetings Section 2.1 Procedure – Purchasing Guidelines Section 8.1 Procedure – Verification of Subcontracted Product Section 8.3 Procedure – Design Outsourcing Section 15.3 Level 1 – Purchasing Process Section 7.4.1 Level 1 – Purchasing Information Section 7.4.2 Level 1 – Analysis of Data Section 8.4

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8.3 Verification of Subcontracted Product

PURPOSE To monitor and verify purchased product at subcontractor’s premises. SCOPE This procedure applies to all subcontracted work of Proper Group International. RESPONSIBILITY The scheduling department or manufacturing engineering p1 has overall responsibility for adherence to this procedure.

PROCEDURES When work is being subcontracted: routers, data or prints for quoting are sent out to approved suppliers.

A Supplier Request For Quote Form 8.3 outlining specific project specifications may also be sent out with the data or prints, if required.

Once all quotes are returned to Proper Group International, the scheduling associate or manufacturing

engineer reviews them for timing and price. After the review, a subcontractor is selected to do the work. A Purchase Requisition Form 8.1 is filled. Once the appropriate personnel approve this, it is forwarded

to the subcontractor. If the subcontracted work requires use of data, a Data Request Form 9.1 is also filled out and given to

the data management department. Data management will then send out the latest data to the selected subcontractor.

The scheduling associate or manufacturing engineer contacts the subcontractor at least once a week to

see how the project is progressing. If a project takes longer than five weeks to build and if timing is critical, timelines are required from the

subcontractor. The scheduling associate visits the subcontractor periodically to monitor and verify the subcontracted

work if adequate electronic proof of completion has not been provided. If there are any issues, a hit list is made up and the scheduling department reviews the project. An

updated schedule is then generated if required.



Rev: Form 8.3 is sent out only if req’d, subcontractors visited if req’d. Action Plan form omitted.

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8.3 Verification of Subcontracted Product (continued) In the event the subcontractor falls below the Proper Group International Standards, the Vendor

Guidelines Procedure 8.2 is followed. RELATED DOCUMENTATION Form – Purchase Requisition 8.1 Form – Subcontractor Work Specifications 8.2b Form – Supplier Request for Quote 8.3 Form – Data Request 9.1 Procedure – Manufacturing Process Plan Phase – Aerospace Section 3.8.5 Procedure – Vendor Guidelines Section 8.2 Level 1 – Verification of Purchased Product Section 7.4.3

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8.4 Mold Construction Outsource

PURPOSE To manage, monitor, and verify subcontracted mold construction. SCOPE This procedure applies to all design, design & build, and build only to Proper Tooling provided design complete mold construction work outsourced by Proper Tooling. RESPONSIBILITY The program manager has overall responsibility for adherence to this procedure.

PROCEDURES After a subcontractor is selected to perform mold design and/or construction, a Mold Construction

Outsource Form 8.4 is filled out and sent to the subcontractor along with an authorized purchase order. Other information that is supplied when applicable, along with the Mold Construction Outsource Form

8.4 are: Released and Feasibility Complete Part Data Mold Design (electronic format) Mold Surfaces (electronic format) Project APQP Plan Form 3.3 Design Outsource Checklist Form 15.3 Proper Tooling Engineering Manual (release is required)

Progress reports must be submitted electronically (Microsoft Project) weekly from the subcontractor to

Proper Group International. It is the program manager’s responsibility to follow up and ensure these weekly progress reports are received, and forwarded to scheduling.

If the project is behind schedule, the program manager meets with the outsource company and a

modified plan is determined and forwarded to the Proper Tooling scheduling department as well as the program manager responsible for the project.

Information will be in a Microsoft Project or equivalent format. In the event the subcontractor falls below the Proper Group International standards, the Vendor

Guidelines Procedure 8.2 is followed.

Issuing Dept. Officer Established Revision Rev # Purchasing 05/20/02 02/01/09 005

Rev: Scheduling dept responsible for outsource schedule.

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8.4 Mold Construction Outsource For design and build projects, it is the program manager’s responsibility to ensure that the supplier has

submitted the mold design and surface files on or before the arrival of the mold. A Data Request Form 9.1 will be executed to transfer the files into the proper directory in Proper Group International’s system.

RELATED DOCUMENTATION Form – Project APQP Plan 3.3 Form – Mold Construction Outsource 8.4 Form – Data Request 9.1 Form – Design Outsource Checklist 15.3 Procedure – Vendor Guidelines Section 8.2 Level 1 – Design and Development Planning Section 7.3.1

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8.5 Vendor Charge Back

PURPOSE To make sure all inferior products or services, which require adjustments to the agreed price are recorded and credited to the correct account. SCOPE All products and/or services rendered. RESPONSIBILITY All associates who are responsible for the outsourcing of products and/or services.

PROCEDURES All products and/or services that have been subcontracted must be inspected to ensure they fulfill the

original agreement. When a product / service does not meet the original agreement, a total cost to correct and complete the

product or service must be established. This amount will be entered on a Subcontracting Backcharge Form 8.5.. The Subcontracting Backcharge Form 8.5 will need to be completed with all required information, and

distributed to accounts payable, the program manager, and the master job file. If the product or service has not been invoiced or paid, the amount to be backcharged can be entered as

a credit. Examples of backcharging a vendor are: not completing the job job is not correctly completed and has to be fixed by Proper Group International or another vendor missing the due date

RELATED DOCUMENTATION Form – Vendor Charge Back 8.5 Procedure – Incoming / In Process Components & Material Inspection & Non Conformity Guidelines Section 6.2 Issuing Dept. Officer Established Revision Rev #

Purchasing 03/01/03 02/01/09 002

Rev: logo and name change

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DATA MANAGEMENT (Section 9) 9.1 Incoming Data & Naming Convention PURPOSE This is a guideline for documenting and distributing incoming data. SCOPE This is a company wide standard defining the steps in processing incoming data. RESPONSIBILITY Overall responsibility for control of incoming data is given to the Data Management Leader. DEFINITIONS Data – any pictorial information, electronic or paper, used to manufacture a mold, or used for product design. PROCEDURE

Incoming Data - General The data management department will receive all incoming data. All data refers to part prints, and electronic data, which are used in day-to-day business. All data received paper or electronic forwarded to the data management department should have a Data

Request Form 9.1filled out in its entirety by the requesting party. In the event data is received directly from the customer to data management, an email will be sent by

data management to estimating, as well as the appropriate sales associate and program manager informing them of the data arrival and requesting a Data Request Form 9.1.

If no response is received from the email notification by the close of business of the day following the

original notification, a second notice will be sent by data management to the original group, and copied to the director of program management and costing to assure that data will be claimed.

All incomplete requests will be returned to the original requester! All other incoming data will be stored in the quote directory until proper identification is obtained.


Established Revision Rev # Data Management 09/05/00 01/19/09 007

Rev: Changed dept names to be current.

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DATA MANAGEMENT (Section 9) 9.1 Incoming Data & Naming Convention (continued) The Data Request Form 9.1 is to be used for one specific purpose only. In other words, if data is used

to quote a new mold and an engineering change, two separate Data Request Forms 9.1 are required.

Logging Incoming Data Electronic Data When electronic data is received, it will be read into the computer system and identified per the product

file naming convention. This data will then be logged into the Data Management Weekly Log Form 9.1aalong with the proper

screen copy documentation. Paper Data with Job Number All paper data pertaining to active jobs is logged into the Data Management Weekly Log Form 9.1a. Paper data related to the final part of product that has not been received electronically will be stamped

with a Received stamp and dated.

The paper data will then be forwarded to the Design Group for Storage. The program manager may obtain a copy of the paper data from the Design Group if further action is

required using the data. A Change Order Form 3.15 will be written by the program manager listing all action and will be

distributed to the design, EDM, and quality control departments. NOTE: Customer supplied part prints are for reference only unless accompanied by a Change Order Form 3.15 or the Project APQP Plan Form 3.3.

Processing Incoming Data Verification All incoming math data is stored in the quote directory in monthly sub-directories.

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DATA MANAGEMENT (Section 9) 9.1 Incoming Data & Naming Convention

Purpose of Data Quoting All incoming data marked for quoting will be identified by customer, file name, file type and date. It will

be placed into the Quote directory. The data management reviews the data for completeness. Either screen copy documentation or plots

are forwarded to the estimating department per instructions on the Data Request Form 9.1. Job Kick Off – Tooling All incoming tooling data marked for job kick off will be identified as status being “NR”, renamed

including job number, file name, NR, date, and placed into the job number / part directory. The Core Engineering Group will compare and identify all tooling changes to be released for job kick-off,

from the quote tooling data (part, print) specified on the quotation (if not previously completed). The original quote file name must be on the Data Request Form 9.1.

If incomplete data is received, the Core Engineering Group will document what data was received and

forward it to the requesting party. A Change Order Form 3.15 must be issued to change the status from “NR” to Released and be

distributed with a copy of the original Data Request Form 9.1. If a Change Order Form 3.15 is issued, the three digit numerical status will match the change order

when the file is renamed for release. (Change Order 001 is the release change order) Engineering Change The program manager completes a Data Request Form 9.1 including the data availability and file name,

and forwards it to the data management department. The data management associate records the original file name and forwards the form to the appropriate

group for overlaying the current released data to the newly received data for an engineering change. The data management associate in possession of the Data Request Form 9.1 will rename the file as

status being NR, renamed including the job number, NR, file type, date, and place the file in the job number part directory. Also, place the native part file in the part directory under the project job number.

When completed with the overlay, the completed Data Request Form 9.1 with all attached overlay

screen captures are to be forwarded to the data management and program management groups.

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DATA MANAGEMENT (Section 9) 9.1 Incoming Data & Naming Convention (continued) A Change Order Form 3.15 must be issued to change the status from NR to release. This Change

Order Form 3.15 must include the engineering change data date only; and then distributed with a copy of the original Data Request Form 9.1. The data management group will not release the file if the Data Request Form 9.1 and screen dumps are not on file or attached to the Change Order Form 3.15.

Examples of Filenames Engineering Change (before the Change Order)

11476_nr_sr_customer’s file name_05apr03.prt Released (after Change Order)

11476_c003_sr_customer’s file name_05apr03.prt The three digit numerical status will match the Change Order Form 3.15 within the file name when the

file is renamed for release. Inspection All data used for inspection data must be released data and will be placed into the following directory:

job number / master / QC Product Design – (Proper Technologies Personnel Only) Upon the award of a new project, the Data Request Form 9.1, must be filled out indicating the “kick off”

box on the form. If new data is not received at kick-off, this form must still be filled out to utilize currently logged in data.

Upon receipt of the Data Request Form 9.1 and the assigned project number, the data management

group will move the data (retaining the original filename) from the quote directory, to a subdirectory under the “IN” subdirectory (using the original date the data was received as the folder name, ie. ddmmyy) of the specific project directory.

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DATA MANAGEMENT (Section 9) 9.1 Incoming Data & Naming Convention

File Naming Convention All data files will have the date that the file was received placed in the file name. This date cannot be

changed, with the exception of files received on Friday after 3:00 p.m. which will be dated as being received on the following Monday.

The following naming convention will be adhered to for all incoming tooling data. See charts for file

naming convention breakdown located at the end of this section.

Examples of Filenames Estimating Files Filename_Date.extension

ABC_XYZ123_COWL_WR_05APR99.PRT Released Part Files

3700L_C000_WR_05APR99.PRT

Left or Right File Type Extension Hand Data (See Chart) (See Chart) If Required Customer’s File Name

Job Status Date Number (See Chart) (See Chart)

Customer Part Name Date (See Chart)

Customer File File Type Extension Name (See Chart) (See Chart)

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DATA MANAGEMENT (Section 9) 9.1 Incoming Data & Naming Convention (continued) Partial Files A “P” will precede the File Type section of the filename. For example, a partial wireframe file could look like this:

_3700L_C001_PWR_05APR99.PRT Proper Group International Generated Data (Product Development) A “Proper" will precede the File Type section of the filename. A wireframe file generated by Proper Group International could look like this:

3700L_C002_PMEWR_Customer’s File Name_05APR99.PRT Proper Group International Generated Data (Product Development) A “Proper" will precede the File Type section of the filename. A wireframe file generated by Proper Group International could look like this:

3700L_C002_PMEWR_ Customer’s File Name_05APR99.PRT Reference Data An “REF” will precede the filename. A wireframe file to be used for reference could look like this:

REF_3700_WR_ Customer’s File Name_05PAR99.PRT

Prefix (See Chart)

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DATA MANAGEMENT (Section 9) 9.1 Incoming Data & Naming Convention (continued)

PREFIX STATUS PREFIX DESCRIPTION NAME STATUS p Partial Data nr Not Released Proper Proper Created Data/Revised c001 Release ref Reference Data cxxx Change Order Number Vendor Abbreviation

FILE TYPE

NAME DESCRIPTION wr Wireframe Only wo OSM Wireframe Only wi ISM Wireframe Only sr Surface Only so OSM Surface Only si ISM Surface Only sc Sections Only dt Wireframe, Surface, & Section sd Solids

DATE ABBREVIATION ABBREVIATION MONTH ABBREVIATION MONTH jan January jul July feb February aug August mar March sep September apr April oct October may May nov November jun June dec December

EXTENSION

NAME SYSTEM .cat CATIA, CatPart, Model, Cat Drawing .igs IGES .prt UniGraphics .$ CGS .3d CimLinc 3D .cad CimLinc 2D no extension PDGS _ck.prt CADKey .prt IDEAS .elt Cimatron .prt1 Pro E

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DATA MANAGEMENT (Section 9) 9.1 Incoming Data & Naming Convention (continued)

File Naming Convention – Product Design (Proper Technologies Personnel Only) All product data files that are received will retain their original file name. The naming convention for deliverable product data will be directly driven by the customer’s standards. Whenever data for a new job (tool) start from the product group is released to the tooling group, a Data

Request Form 9.1 will be filled out by Proper Technologies and a copy will be sent to the tooling program management group.

At this time, the Proper Group International Job Kick Off Procedure 3.6 will apply. RELATED DOCUMENTATION Form – Project APQP Plan 3.3 Form – Change Order 3.15 Form – Change Order – Aerospace 3.15.5 Form – Data Request 9.1 Form – Data Management Weekly Log 9.1a Procedure – Document Control Section 7.1 Procedure – Mold Construction Outsource 8.4 Procedure – Product Design Section 18.1 Procedure – Product Design Changes Section 18.2 Procedure – Product Design Verification and Validation Section 18.3 Level 1 – Control of Documents Section 4.2.3

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DATA MANAGEMENT (Section 9) 9.2 Manufacturing Release

PURPOSE This is a guideline for supplying the manufacturing group with a release document in conjunction with an appropriate CAD file to begin or continue manufacturing on a subject job. SCOPE This is a core manufacturing department standard that includes manufacturing for all divisions of Proper Group International. RESPONSIBILITY The core manufacturing supervisor has the responsibility of ensuring this procedures is adhered to and is presented to the manufacturing department using the supplied standards. PROCEDURE The Manufacturing Release Form 9.2 is completed showing the Proper Group International job number,

file name, description, and a screen dump showing needed “pick-up” dimensions for each file that is released to the manufacturing area.

The Manufacturing Release Form 9.2 is completed and released after the CNC surfacing approvals are

completed and reviewed by the appropriate design leader or supervisor. The screen dump is marked up with the following items noted: Work line intersection. Start numbers from workline intersection to workpiece “0” pickup position. Overall size of workpiece dimensioned.

The screen dump must show a view of the workpiece along with any needed dimensional pick-ups that

are not contained in the data or on the prints. Upon completion of the surfacing phase, the Manufacturing Release Form 9.2 is saved in the (_release)

directory under the appropriate job number. If the file name on the Manufacturing Release Form 9.2 is over Change Level 001, the manufacturing

associate has the responsibility of reviewing all change orders prior to CNC cutting the workpiece. Upon completion of CNC cutting the workpiece, the manufacturing associate has the responsibility of

validating the workpiece with X, Y, Z point checks an documenting the checks on the Manufacturing Release Form 9.2 in the directory under the appropriate job number.


Established Revision Rev # Engineering 03/01/02 02/01/09 006

Rev: Added further detail for the validation process on form 9.2

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DATA MANAGEMENT (Section 9) 9.2 Manufacturing Release (continued) The core manufacturing supervisor of manufacturing will advise the points that should be validated.

The manufacturing associate will enter their employee number in the “checked by” field of the

Manufacturing Release Form 9.2 to acknowledge that the validation process has been completed.

If any points check out of tolerance, the actual dimension is recorded in the “actual” cell on the form and the core manufacturing supervisor will be notified to give direction on corrections that may be required.

CNC operators are prohibited from altering the axis system of a released CNC cut file. If any alterations are required, it must be completed by the core manufacturing department and a new

Manufacturing Release Form 9.2 must be released. RELATED DOCUMENTATION Form – Manufacturing Release 9.2 Level 1 – Design and Development Outputs Section 7.3.3. Level 1 – Control of Production and Service Provision Section 7.5.1

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DATA MANAGEMENT (Section 9) 9.3 Data Transfer Profile PURPOSE This is a guideline for documenting and storing customer and vendor CAD capabilities and preferences. SCOPE This is a company wide standard defining the procedure for entering and storing data transfer profiles. RESPONSIBILITY It is the overall responsibility of the data management department for creating and maintaining data transfer profiles. PROCEDURE Creating a Data Transfer Profile A Data Transfer Profile Form 9.3 is created for all active customers, new customers, and any vendors

that require the transfer of electronic data. Any associate that requires a Data Transfer Profile Form 9.3 for a new customer or vendor, must fill out

a Data Transfer Profile Form 9.3 and submit it to the data management department. The data management department will then create an electronic form and save it to the server using the

proper naming convention. The data management department will be responsible for maintaining and updating the master file

directory containing all customer and vendor information. Data Transfer Profile Form 9.3 File Location A directory will be created in the following directory and will contain the following information: F:\quoting_data_mgt_\data management\data transfer profile Data Transfer Profile Form 9.3 containing all Proper Group International data transfer information Data Transfer Profile Form 9.3 containing all Proper Group International customer data transfer

information


Established Revision Rev # Data Management 07/15/02 02/01/09 002

Rev: Updated directory location.

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DATA MANAGEMENT (Section 9) 9.3 Data Transfer Profile Supplying New Customers / Vendors with PME Data Transfer Information Any time a new customer or vendor requests information on how to transfer data with Proper Group

International, the Data Transfer Profile Form 9.3 filled out with the Proper Group International data management information will be forwarded to the requester. File name: Form 9.3_Proper Group International.

RELATED DOCUMENTATION Form – Data Transfer Profile 9.3

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DATA MANAGEMENT (Section 9) 9.4 CAD Data Conversion Verification PURPOSE This procedure defines the process for verifying CAD data accuracy when converted from a customer’s native language to a different language for manufacturing or inspections purposes. SCOPE Proper Aerospace RESPONSIBILITY It is the responsibility of the sales associate or program manager to identify all programs or revisions that require data conversion verification per the customer’s purchase order or customer’s standards. The Project APQP Plan Form 3.3.5 and Change Order Form 3.15.5 will be used to communicate this need throughout the organization. The data management department is responsible to insure this process is completed as detailed below. PROCEDURE

The sales associate will identify all projects that require CAD data conversion verification by identifying it

on the Project APQP Plan Form 3.3.5 in the appropriate check box. Authorizing the release of data to manufacturing is the program manager’s responsibility. He/she will identify the verification requirement by checking the appropriate box on the Change Order

Form 3.15.5 which directs data management to release the data to manufacturing. CAD data management will verify all data as directed by the change order. Several boundary locations shall be identified in the native language and their coordinates entered on the

Data Verification Form 9.4. The data will then be converted to the CAD language required for manufacturing. The same boundary locations shall have their coordinates obtained from the manufacturing language and

entered on the Data Verification Form 9.4 for comparison. The difference in locations can not exceed 25% of the smallest tolerance required by the part design. If

part design tolerances are not available the tolerance shall not exceed .002” or .05 mm.


Established Revision Rev # Data Management 01/19/09 Release

Rev: New Procedure & Form

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DATA MANAGEMENT (Section 9) 9.4 CAD Data Conversion Verification (continued) If the converted data meets the tolerance, the Data Verification Form 9.4 shall be completed with the

name of the person approving the files, dated and saved in the project folder. The converted data can then be released to manufacturing.

If the converted data does not meet the tolerance, the Data Verification Form 9.4 shall be completed with

the name of the person rejecting the files, dated and saved in the project folder. The program manager will be notified of the rejection and the converted data shall be deleted. Non-

approved data can not be released to manufacturing. RELATED DOCUMENTATION Form – Project APQP Plan 3.3.5 Form – Change Order 3.15.5 Form – Data Verification 9.4

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CONTROL PLAN-FMEA (Section 10) 10.1.5 Manufacturing Control Plans PURPOSE The manufacturing of components controlled by the First Article Process require a process control plan. The control plan will be documented in the form of a Work Order Router Form 3.8.5. SCOPE Proper Aerospace RESPONSIBILITY Manufacturing / engineering will create a work order router that insures customer requirements and specifications are met during the manufacturing process. PROCEDURE The Work Order Router Form 3.8.5 is used on all components that are controlled by a First Article

Process Procedure 6.9.

The Work Order Router Form 3.8.5 documents each step of the manufacturing process and provides checks and balances to control each process.

A representative from manufacturing, engineering, and quality will review and approve the Work Order

Router Form 3.8.5 prior to release for manufacturing.

All revisions to the Work Order Router Form 3.8.5 must be documented and approved by a quality representative.

RELATED DOCUMENTATION Form – Work Order Router 3.8.5 Procedure – First Article Process Section 6.9 Level 1 – Measurement, Analysis & Improvement – General Section 8.1 10.1 Tool Construction Control Plans PURPOSE


Established Revision Rev # Control Plan / FMEA 02/01/09 Release

Rev: new Aerospace procedure

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CONTROL PLAN-FMEA (Section 10) All new production tooling requires a generic control process plan. This procedure outlines both generic and project specific control plans used on all molds. SCOPE This applies to all new production molds at Proper Tooling. RESPONSIBILITY The general manager of manufacturing along with a cross functional team is responsible for maintaining and updating the generic Tool Construction Control Plan Form 10.1. Project specific control plans are the responsibility of the scheduling department. PROCEDURE The Tool Construction Control Plan Form 10.1 is used for all new production tools. Any modifications

required throughout the lifetime of the program are to be documented by the general manager of manufacturing and are updated as required (this is a living document).

This control plan is used in the manufacturing process plan meetings as reference (Reference –

Manufacturing Process Plan Phase Section 3.8). A project specific control plan is then carried forward utilizing the Manufacturing Process Plan Phase

Procedure 3.8. If revisions are not required, the general manager of manufacturing reviews the Tool Construction

Control Plan Form 10.1 once per year and a revision date is added showing a review has been completed.

RELATED DOCUMENTATION Form – Tool Construction Control Plan 10.1 Procedure – Manufacturing Process Plan Section 3.8 Level 1 – Measurement, Analysis, & Improvement – General Section 8.1 10.2 DESIGN FMEA PURPOSE


Established Revision Rev # Control Plan / FMEA 01/01/01 02/01/09 004

Rev: updated with new logo and company name

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CONTROL PLAN-FMEA (Section 10) All new production tooling requires a generic design FMEA. This procedure outlines both generic and project specific design FMEAs used on all molds. Products controlled by a First Article Process will not be designed by Proper Group International. SCOPE This applies to all production molds at Proper Group International. RESPONSIBILITY The design supervisor / manager along with a cross functional team is responsible for maintaining and updating the generic Design FMEA Form 10.2. Project specific design FMEAs are the responsibility of the design department. PROCEDURE The Design FMEA Form 10.2 is used for all production tools. Any modifications required throughout the

lifetime are to be documented by the design supervisor / manager and are updated as required (this is a living document).

This Design FMEA Form 10.2 is used in the Kick Off / Pre Kick Off Phase Section 3.6 and the Concept

Phase Section 3.7. If revisions are not required, the design supervisor / manager and the cross functional team reviews the

Design FMEA Form 10.2 once per year and a revision date is added showing a review has been completed.

RELATED DOCUMENTATION Form – Design FMEA 10.2 Form – Design FMEA Severity 10.2a Form – Design FMEA Occurrence 10.2b Form – Design FMEA Detection 10.2c Procedure – Kick Off / Pre Kick Off Phase Section 3.6 Procedure – Concept Phase Section 3.7 Level 1 – Measurement, Analysis and Improvement – General Section 8.1



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CONTROL PLAN-FMEA (Section 10) 10.3 Process FMEA PURPOSE All new production tooling requires a generic process FMEA. This procedure outlines both generic and project specific process FMEAs used on all molds. SCOPE This applies to all new production molds at Proper Group International. RESPONSIBILITY The general manager of manufacturing along with a cross functional team is responsible for maintaining and updating the generic Process FMEA Form 10.3. Project specific process FMEAs are the responsibility of the scheduling department. PROCEDURE The Process FMEA Form 10.3 is used for all new production tools. Any modifications required

throughout the lifetime of the program are to be documented by the general manager of manufacturing and are updated as required (this is a living document).

This Process FMEA Form 10.3 is used in the manufacturing process plan meetings as reference

(Reference Manufacturing Process Plan Phase Section 3.8). A project specific control plan is then carried forward utilizing the Manufacturing Process Plan Phase

Section 3.8. If revisions are not required, the general manager of manufacturing and the cross functional team

reviews the Process FMEA Form 10.3 once per year and a revision date is added showing a review has been completed.

RELATED DOCUMENTATION Form – Process FMEA 10.3 Form – Process FMEA Severity 10.3a Form – Process FMEA Occurrence 10.3b Form – Process FMEA Detection 10.3c Procedure – Manufacturing Process Plan Section 3.8 Level 1 – Measurement, Analysis and Improvement – General Section 8.1




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FACILITIES MANAGEMENT (Section 11) 11.1 Facilities Maintenance PURPOSE To have a dedicated department for the preservation, predictive maintenance, and preventive maintenance of facilities and equipment. SCOPE All equipment and facilities of Proper Group International. RESPONSIBILITY The facilities manager has the overall responsibility. Department Responsibilities The control of the following personnel: housekeeping and janitorial machine maintenance facilities maintenance

To contract and control all outside subcontractors used for facilities and equipment maintenance. To contract all preventive maintenance contracts to outside vendors. To develop and maintain preventive maintenance programs on all key process machinery. To respond and complete all maintenance requests forwarded to this department. To maintain up to date training for the personnel in this department.

RELATED DOCUMENTATION Level 1 – Infrastructure Section 6.3 Level 1 – Work Environment Section 6.4


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FACILITIES MANAGEMENT (Section 11) 11.2 Preventive Maintenance PURPOSE To document and control the preventative maintenance program for machinery. SCOPE All machinery that requires preventive maintenance at Proper Group International. RESPONSIBILITY It is the responsibility of the maintenance supervisor to create and maintain a preventive maintenance program. PROCEDURE Preventive maintenance will be performed as required per our Scheduled Maintenance Checklist Form

11.2. The maintenance supervisor will generate the schedule for preventative maintenance. The Scheduled Maintenance Checklist Form 11.2 will be used by the maintenance associates and the

machine operators in order to ensure that all machines are maintained. Once the schedule maintenance is completed, the maintenance associate and machine operator will

sign and date the Scheduled Maintenance Checklist Form 11.2. Documentation The maintenance supervisor maintains all forms and paperwork. RELATED DOCUMENTATION Form – Scheduled Maintenance Checklist Form 11.2 Level 1 – Infrastructure Section 6.2 Level 1 – Work Environment Section 6.3



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FACILITIES MANAGEMENT (Section 11) 11.3 Maintenance Requests

PURPOSE To document and control all facility and machinery maintenance. SCOPE All facility and machinery maintenance at Proper Group International. RESPONSIBILITY The maintenance supervisor is responsible for receiving the maintenance requests, for setting the priority on requested maintenance and for the dispatching of duties. PROCEDURE The first step in the maintenance process is to fill out a Help Desk Ticket (through the Help Desk

Software) or Maintenance / Safety Request Form 11.3. Both of these methods are used for all required maintenance.

After the Maintenance / Safety Request Form 11.3 is filled out, it is then forwarded to the maintenance

department. (The Help Desk Ticket is automatically sent to the maintenance department). Once the Maintenance / Safety Request Form 11.3 is received, the maintenance supervisor will log the

information into the Help Desk software. The maintenance supervisor assigns a priority to each maintenance request, and also for scheduled

maintenance. Each maintenance associate will receive a printed Help Desk Ticket along with a line up for the

requirements to complete the task. Upon completion, the Help Desk Ticket is returned to the maintenance supervisor listing corrections

and/or required actions and a completion date. This information is then entered into the Help Desk software. 11.3 Maintenance Requests



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FACILITIES MANAGEMENT (Section 11) RELATED DOCUMENTATION Form – Maintenance / Safety Request 11.3 Level 3 Safety Manual – Safety Committee Section 1.1 Level 1 – Infrastructure Section 6.3 Level 1 – Work Environment Section 6.4 Reference – Help Desk Software

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FACILITIES MANAGEMENT (Section 11) 11.4 Building Maintenance PURPOSE This procedure ensures a safe and maintained building for all associates and its contents. SCOPE All buildings owned or occupied by Proper Group International. RESPONSIBILITY The facilities maintenance supervisor is responsible for overseeing and scheduling the appropriate personnel and/or contractors. PROCEDURE All fire supervision systems are to be checked quarterly by a certified individual or company. Roof systems and walls are to be corrected for any water or cosmetic issues as they arise. Safety inspections (reference Safety Manual).

The logistics supervisor is responsible for overseeing the following:

Personal dedicated to daily housekeeping.

Annual house cleaning of all facilities.

Landscape and parking areas to be cleaned and maintained.

RELATED DOCUMENTATION Level 1 – Work Environment Section 6.4 Level 3 – Safety Manual



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MOLD CERTIFICATION (Section 12) 12.1 Mold Certification & Acceptance PURPOSE To outline a specific procedure for mold certification and acceptance. This procedure encompasses many facets between program management, manufacturing and customer interaction. SCOPE This applies to all production molds / tools manufactured by Proper Tooling. RESPONSIBILITY It is the responsibility of the program manager, manufacturing, and processing departments for adherence to this procedure. PROCEDURE The procedures outlined are developed in the following phases:

See Tryout Scheduling / Pre Sampling Phase Section 3.21 of the Proper Group International Procedures Manual.

Pre Sampling Phase

This phase gives direction to all appropriate parties in the preparing of the initial preliminary samples for T1.

Initial Mold Inspection Phase Inspection of the mold is to be completed by manufacturing and documented on the Mold Inspection For

Tryout Form 12.2 to allow shipment of the mold to the tryout facility or internal tryout department.

T1 Mold Performance Evaluation Phase This is the sampling of our initial T1 tryout During this sampling the Proper Tooling program manager and process engineer will evaluate mold

performance. (See Tryout Scheduling / Pre Sampling Phase Section 3.21 and Tryout Instructions Section 3.23).

The Mold Performance Evaluation Form 12.4, Mold Performance Evaluation Form 12.4c, and the Part

Performance Evaluation Form 12.4d will be completed outlining tool function, part quality, dimensional accuracy and delivery. (See Mold Performance Section 12.4).


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MOLD CERTIFICATION (Section 12) 12.1 Mold Certification & Acceptance (continued) Proper Tooling will document tryout issues on the Open Issues Action Plan Form 3.6. The appropriate

samples will be compiled for evaluation. (See Mold Tryout Open Issues Section 12.3)

See Post Sampling Phase Section 3.10 of the Proper Group International Procedures Manual. Our post sampling phase is conducted by program management outlining results of the initial sampling and documenting further modification or enhancement required by Proper Tooling or the customer.

Post Sampling Phase

Generally all molds are inspected through our quality control department for dimensional accuracy. (See Final Dimensional Certification Section 12.5).

T2 or Additional Sampling This will be performed as required continuing with the post sampling phase as described above.

Final Mold Inspection Manufacturing to review customer standards and prepare the mold for final shipment utilizing the Mold

Inspection For Shipment Form 12.6, additional customer standards, past Proper Tooling Change Orders Form 3.15, and all other related documentation.

The Customer Acceptance Form 12.7 is to be signed off outlining the customer’s acceptance of tool

performance. Upon completion of all phases and customer acceptance, the mold will be prepared for shipment.

Documentation Completion

The quality department is in charge of holding all documents throughout the mold certification and acceptance process.

Upon shipment, the customer will be sent a copy of the process sheets within three weeks.

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MOLD CERTIFICATION (Section 12) 12.1 Mold Certification & Acceptance RELATED DOCUMENTATION Form – Change Order 3.15 Form – Open Issues Action Plan 3.6 Form – Mold Inspection For Tryout 12.2 Form – Mold Performance Evaluation 12.4 Form – Mold Performance Evaluation 12.4c Form – Part Performance Evaluation 12.4d Form – Mold Inspection For Shipment 12.6 Form – Customer Acceptance Form 12.7 Procedure – Post Sampling Phase Section 3.10 Procedure – Tryout Scheduling / Pre Sampling Phase Section 3.21 Procedure – Mold Tryout Open Issues Section 12.3 Procedure – Mold Performance Evaluation Section 12.4 Procedure – Final Dimensional Mold Certification Section 12.5 Level 1 – Monitoring and Measurement of Product Section 8.2.4

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MOLD CERTIFICATION (Section 12) 12.2 Mold Inspection For Tryout PURPOSE To inspect completed molds for a primarily T1 level tryout and any subsequent tryouts afterwards until shipment. SCOPE This applies to all production and prototype molds / tools manufactured by Proper Tooling. RESPONSIBILITY It is the responsibility of the manufacturing associate supervisor / manager, and mold leader for adherence to this procedure. PROCEDURE Upon completion and initial assembly of all prototype and production molds, the Mold Inspection For

Tryout Form 12.2 must be completed to ensure proper review of a mold / tool is done to ensure a successful tryout.

The mold leader in charge of manufacturing the mold will do the initial completion of the Mold Inspection

For Tryout Form 12.2. Upon completion of the form, the mold leader will notify the manufacturing supervisor/manager to do a

second review and approval of the mold. After both reviews are completed, both associates must sign the Mold Inspection For Tryout Form 12.2. Once the form is approved it is forwarded to the tryout department. The form is then filed in the tryout department job file. RELATED DOCUMENTATION Form – Mold Inspection For Tryout 12.2 Procedure – Shipping & Receiving Customer Tools Section 5.1 Procedure – In Process Inspection Section 6.1 Procedure – Mold Certification & Acceptance Section 12.1 Level 1 – Monitoring and Measurement of Product Section 8.2.4



Rev: Form 12.2 is forwarded to the tryout dept and no longer shipping.

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MOLD CERTIFICATION (Section 12) 12.3 Mold Tryout Open Issues PURPOSE This procedure establishes the methods of checking the progress from T-1 to the final tryout of each mold to eliminate potential process / functional problems. SCOPE This function will include all tryouts from a mold. RESPONSIBILITY It will be the combined responsibility of the program manager, process engineer and the quality department. PROCEDURE A manual check of the first part(s) is completed to dimensionally confirm radii, wallstock thickness at key

areas, and other characteristics of the first part. A visual check of the first part(s) to verify that all ribs are filled and to identify any other hard to fill areas. A visual check of the first part(s) will be made to determine deficiencies such as flash, warpage, sink

marks, indications of temperature extremes, and other appearance deficiencies. The process engineer and program manager complete their appropriate areas of the Mold Performance

Evaluation Form 12.4c and Part Performance Evaluation Form 12.4d.

Any open issues resulting from these will transfer to the Open Issues Action Plan Form 3.6. The program manager enters any additional open issues directly to Open Issues Action Plan Form 3.6.

At the post sample phase meeting (reference Procedure Post Sampling Phase Section 3.10), if there

are any deficiencies, the program manager will incorporate the changes by completing a Change Order Form 3.15.

At the customer’s request, a first part will be checked dimensionally to mold inspection points.



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MOLD CERTIFICATION (Section 12) 12.3 Mold Tryout Open Issues RELATED DOCUMENTATION Form – Change Order 3.15 Form – Open Issues Action Plan 3.6 Form – Mold Performance Evaluation 12.4c Form – Part Performance Evaluation 12.4d Procedure – Post Sampling Phase Section 3.10 Procedure – Tryout Scheduling Section 3.21 Procedure – Tryout Instructions Section 3.23 Procedure – Mold Certification Acceptance Section 12.1 Level 1 – Control of Production and Service Provision Section 7.5.1

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MOLD CERTIFICATION (Section 12) 12.4 Mold Performance PURPOSE This procedure describes the process of evaluating mold performance. SCOPE All PME Companies. RESPONSIBILITY It is the responsibility of the process engineer and the quality department. PROCEDURE When a mold is having a tryout for the first time, the process engineer fills out a Mold Performance

Evaluation Form 12.4. The Mold Performance Evaluation Form 12.4 is filled out using the rating scale listed on the form. The

categories that are rated are: Delivery Phase Tool Function Part Quality

The process engineer will forward copies of the Mold Performance Evaluation Form 12.4 to the quality

department to rate the molds for dimensional accuracy. As the quality department rates the molds, they will fill out their copy of the Mold Performance

Evaluation Form 12.4, and return the form to the process engineer. The process engineer will then update the records in his / her department, and also forward the copy

to the corporate quality associate. The original Mold Performance Evaluation Form 12.4 is forwarded to the corporate quality associate

once the tryouts are complete. The Mold Performance Evaluation Form 12.4 is then completed by the corporate quality associate.



Rev: added forms 12.4c & 12.4d, updated to current procedure

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MOLD CERTIFICATION (Section 12) 12.4 Mold Performance (continued) The program manager and process engineer complete the appropriate areas of the Mold Performance

Evaluation Form 12.4c and Part Performance Evaluation Form 12.4d. This is done for each tryout that is required.

During the monthly management meeting, the results from the mold evaluations are reviewed along with many other topics about the company’s on-time performance. These topics are discussed to see how to improve characteristics, processes, etc that are not up to the company and customer’s expectations.

A master copy of all the Mold Performance Evaluation Form 12.4 and the Mold Performance Evaluation

Report Form 12.4a is located in the president’s office. As each month is completed, the corporate quality associate completes the Mold Performance

Evaluation Summary 12.4b. RELATED DOCUMENTATION Form – Mold Performance Evaluation 12.4 Form – Mold Performance Evaluation Report 12.4a Form – Mold Performance Evaluation Summary 12.4b Form – Mold Performance Evaluation 12.4c Form – Part Performance Evaluation 12.4d Procedure – Management Review Meeting Section 2.1 Procedure – Mold Certification & Acceptance Section 12.1 Level 1 – Competence, Awareness and Training Section 6.2.2 Level 1 – Control of Production and Service Provision Section 7.5.1 Level 1 – Measurement, Analysis and Improvement – General Section 8.1 Level 1 – Monitoring and Measurement of Processes Section 8.2.3 Level 1 – Analysis of Data Section 8.4

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MOLD CERTIFICATION (Section 12) 12.5 Final Dimensional Mold Certification PURPOSE This procedure establishes the methods for the final inspection of all molds to ensure compliance to company standards and customer requirements. SCOPE This function will apply to the checking of all significant characteristics of the production molds manufactured at Proper Tooling. RESPONSIBILITY The overall responsibility for final inspection is the quality department. PROCEDURE The quality department determines the appropriate method for final inspection. The final dimensional inspection may be conducted using a CMM, optical inspection machine, or a

variety of measuring hand tools. A certified outsource may also be used when deemed necessary. An inspection of the finished product is conducted, and reports / records are generated.

The following areas are checked: Boss size and locations Slot size and locations Periphery Wallstock surfaces Critical part features Other areas specific to certain tools

When coordinate measuring machine (CMM) inspection points are used to check the mold, they are

from the released surface and wire frame data. The same CMM inspection points are used throughout the program for continuity and traceability of any

deficiencies. These same CMM inspection points are given to the customer upon request for part inspection points.

This procedure allows easy traceability from a part deficiency to the appropriate area on the mold.



Rev: Updated to current procedure, updated/revised areas that are checked.

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MOLD CERTIFICATION (Section 12) 12.5 Final Dimensional Mold Certification (continued) All inspections’ results are reviewed with the program manager. If any corrections are needed a change

order is given to the mold leader to carry out the correction. The mold is returned for re-inspection to confirm that it is within tolerance if required.

If a mold needs to be shipped before a final dimensional inspection can be completed, the program

manager must initial the appropriate box on the Mold Inspection For Shipment Form 12.6 approving the shipment.

Records are kept from the mold certification by job number in the design directory on the network. RELATED DOCUMENTATION Form – Mold Inspection For Shipment Form 12.6 Procedure – Mold Certification & Acceptance Section 12.1 Level 1 – Monitoring and Measurement of Product Section 8.2.4

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MOLD CERTIFICATION (Section 12) 12.6 Mold Inspection For Shipment PURPOSE To inspect completed molds for final shipment to the customer’s production facility. SCOPE Applies to all production molds manufactured by Proper Tooling. RESPONSIBILITY It is the responsibility of the manufacturing supervisor/manager for adherence to this procedure. PROCEDURE Upon initiation of the final assembly of all production molds, the Mold Inspection For Shipment Form

12.6 must be filled out by the mold leader / night shift mold maker to ensure a proper review of the tool is completed to verify customer standards are adhered too.

The mold leader / night shift mold maker will complete the initial report throughout the assembly of the

tool. If the tool is completed on the night shift, the night shift mold maker will follow up with the initialing of the

report throughout the final assembly of the tool. In no way does the day shift or night shift initial for the other with a verbal “it’s complete.” If an area is

suspect it will be rechecked and initialed by the inspecting associate. Upon completion of the assembly and review of the Mold Inspection For Shipment Form 12.6, the mold

leader / night shift mold maker will notify the manufacturing supervisor/manager and the quality control supervisor to do a second review and approval of the mold.

The quality control supervisor is not responsible for all aspects of the Mold Inspection For Shipment

Form 12.6, but is responsible for only part related areas and change order verification, if required. If a mold needs to be shipped before a final dimensional inspection can be completed, the program

manager must initial the appropriate box on the Mold Inspection For Shipment Form 12.6 approving the shipment.

Upon all reviews, the approval signatures will be documented on the form.



Rev: Added Quality supervisor responsible “if required.”

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MOLD CERTIFICATION (Section 12) 12.6 Mold Inspection For Shipment (Continued) The Mold Inspection For Shipment Form 12.6 is forwarded to the shipping and department to start the

shipping process and is also filed in this department. Copies are forwarded to the program management administrative associate. RELATED DOCUMENTATION Form – Mold Inspection For Shipment 12.6 Procedure – Shipping & Receiving Customer Tools Section 5.1 Procedure – Mold Certification & Acceptance Section 12.1 Procedure – Final Dimensional Mold Certification 12.5 Procedure – Customer Acceptance Section 12.7 Level 1 – Monitoring and Measurement of Product Section 8.2.4

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MOLD CERTIFICATION (Section 12) 12.7 Customer Acceptance PURPOSE To document the customer acceptance of the tool’s performance and functionality, surface, fit and finish and tool standards. SCOPE Applies to all production molds manufactured by Proper Tooling. RESPONSIBILITY It is the responsibility of the program manager to obtain customer acceptance and adherence to this procedure. PROCEDURE Upon completion of all mold certification and acceptance phases, and prior to shipment of the mold, the program manager must complete the following: Upon notification from the manufacturing department to program management stating the mold is ready

for shipment and the Mold Inspection Shipment Section 12.6 is complete, the program manager will notify the customer that the mold is ready for final shipment.

The customer may visit the facility for review of the tool and sign off on the Customer Acceptance Form

12.7. If the customer chooses to ship the mold / tool without reviewing the mold in person, the form can be e-

mailed or faxed to the customer for authorization and returned prior to shipment. Upon obtaining customer authorization and acceptance, a copy of the signed Customer Acceptance

Form 12.7 is sent to shipping and receiving along with the Request For Shipment Form 5.1 to authorize shipment.

RELATED DOCUMENTATION Form – Request For Shipment 5.1 Form – Customer Acceptance 12.7 Procedure – Shipping & Receiving Customer Tools Section 5.1 Procedure – Mold Certification & Acceptance Section 12.1 Procedure – Mold Inspection For Shipment Section 12.6 Level 1 – Customer Satisfaction Section 8.2.1 Level 1 – Monitoring and Measurement of Product Section 8.2.4 Issuing Dept. Officer


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RAPID PROTOTYPING (Section 13) 13.1 SLA / LOM Inspection PURPOSE This procedure describes the system for management of stereolithography and laminated object manufacturing models to check for part features and dimensional accuracy. SCOPE This process applies to all in process stereolithography and laminated object manufacturing models whether reworkable or scrap. RESPONSIBILITY The responsibility of inspecting the models is given to the rapid prototype technician and the program manager. PROCEDURE The SLA / LOM Model is inspected for part features and dimensional accuracy. The rapid prototype technician determines if the model is dimensionally accurate and that all features

are present. The SLA / LOM Approval Form 13.1 is then completed. There are three options to choose from: Approved “AS IS” – if the model conforming. Approved with corrections / changes – if the model is nonconforming Is rejected – if the model is not compliant, it will be determined at this time if the model can be

reworked by the program manager. If the model is repairable, the model is tagged with the Red Non Conforming Tag.

The SLA / LOM Approval Form 13.1 is filed in the manufacturing job file. RELATED DOCUMENTATION Form – SLA / LOM Approval 13.1 Level 1 – Monitoring and Measurement of Product Section 8.2.4 Tag – Non Conforming


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RAPID PROTOTYPING (Section 13) 13.2 Rapid Prototype Component Inspection

PURPOSE This procedure describes the dimensional management systems for rapid prototyped components. SCOPE This process applies to all rapid prototyped components prior to shipping. RESPONSIBILITY The responsibility of inspecting the components is given to the rapid prototype technician and the rapid prototype supervisor. PROCEDURE Using the released data file, a technician pulls the necessary master dimensional check points and

labels them accordingly. An ISO drawing of the component with its critical dimension is then generated and inserted into the

Dimensional Check Form 13.2. The master dimensions and the tolerancing (GD&T) are inserted into the Dimensional Check Form 13.2.

GD&T is determined with the customer’s verbal approval. The Dimensional Check Form 13.2 and the Dimensional Checklist Form 13.2a are then forwarded to the

rapid prototype technician. A rapid prototype technician labels each part to be checked with a sequence number starting with Part

#1, Part #2, etc. This labeling will be done with a tag, label or china marker on the back of the part. The rapid prototype technician uses the Dimensional Check Form 13.2 as a guideline for dimensional

check sequence. The rapid prototype technician measures and records the actual dimension of the components and

approves each check by logging the information onto the Dimensional Checklist Form 13.2a. The Dimensional Checklist Form 13.2a is maintained throughout the life of the project. 13.2 Rapid Prototype Component Inspection (continued)


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RAPID PROTOTYPING (Section 13) The original copies of the Dimensional Check Form 13.2 and the Dimensional Checklist Form 13.2a are

forwarded to the supervisor to be filed in the manufacturing job file. RELATED DOCUMENTATION Form – Dimensional Check 13.2 Form – Dimensional Checklist 13.2a Level 1 – Monitoring and Measurement of Product Section 8.2.4

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(Section 14)

MANAGEMENT ORGANIZATIONAL CHART (14.1)

CEO / President

Geoff O’Brien

CFO / Executive Vice President

Mark Rusch

CMO / Executive Vice PresidentTom Ruczynski

METALWORKING POLYMERS

TOOLINGU.S.A.

TECHNOLOGIES

Vice President,Sales & Marketing

Joe Grippe

Vice President of Operations

Bill Little


Steve Carolin

Plant Manager

Mike Palmateer

Assistant Plant Manager

Darren Mack

Plant Manager

Dave Buckley

POLYMERS ANDERSON

Plant ManagerRich Pitoniak

Director of Business

DevelopmentGreg Dante

SALES

TOOLINGCHINA

Vice President

Dave Loehr

Plant Manager

Tiger Zhou

Issuing Dept. Officer Establishe

Revision Rev # Management Organization

02/01/09 01/13/11 004

Rev: Updated Org Chart

RELATED DOCUMENTATION Level 1 – Responsibility & Authority Section 5.5.1

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(Section 14)

MANAGEMENT ORGANIZATIONAL CHART (14.1)

CEO / President

Geoff O’Brien

CFO / Executive Vice President

Mark Rusch

CMO / Executive Vice PresidentTom Ruczynski

METALWORKING POLYMERS

TOOLINGU.S.A.

TECHNOLOGIES


DevelopmentGreg Dante


Bill Little


Steve Carolin

Plant Manager

Mike Palmateer


Darren Mack

Plant Manager

Dave Buckley

POLYMERS ANDERSON


Rich Pitoniak


DevelopmentJoe Grippe

SALES

TOOLINGCHINA

Vice President

Dave Loehr

Plant Manager

Tiger Zhou



02/01/09 08/07/10 003


RELATED DOCUMENTATION Level 1 – Responsibility & Authority Section 5.5.1

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(Section 14)

PROPER TOOLING ORGANIZATIONAL CHART (14.2)

Program Management

Pat Riley

Vice Presidentof Operations

Bill Little

CEO / PresidentGeoff O’Brien

CNC

3 & 5 Axis

EDM

Director of Business Development

Greg Dante

Boring Mill

Gundrill Finalization

Component Details Plates

Sales

Corporate Quality & DevelopmentPatti O’Brien

Design / Engineering

Matt Carson

Plant Manager

Mike Palmateer

Production

Darren Mack

AssemblyOptimizationEng ChangesDennis Marcath

Validation

Tim Riley

Planning / Improvement Dept

Keith Huck

Traditional Machining

Ken Griesbeck

Core Manufacturing

Paul Trujillo

Production Readiness

Tryout Scheduling

Component MachiningMike Spak

Benching

Spotting

Facilities

Personnel

Maintenance

Continuous Improvement

Apprenticeship

Safety

Logistics

Purchasing

DataManagement

Scheduling

Outsourcing

Advanced Technical Department

Jim Lake

Director of Business Development

Joe Grippe

Polyurethane Tooling

Polymers

Injection Molds

Slides & Lifters

RELATED DOCUMENTATION Level 1 – Responsibility and Authority Section 5.5.1


Establishe


02/01/09 Release

Rev: new Aerospace organizational chart.

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(Section 14)

PROPER AEROSPACE- ORGANIZATIONAL CHART (14.3)

Manufacturing EngineeringWayne Jones

General Manager

David Holefiller

Vice President

David Karnes

Sales

Roger Clough

CAM Programming

Jim Simpson

Quality

David Karnes



Establishe


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Rev: new Aerospace organizational chart.

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(Section 14)

PROPER TECHNOLOGIES- ORGANIZATIONAL CHART (14.4)




02/01/09 03/02/09 001

Rev: Removed HR & Quality Systems, Added Fixtures

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(Section 14)

PROPER POLYMERS- ANDERSON ORGANIZATIONAL CHART (14.5)

Maintenance Supervisor

Khol Alexander

Vice President

Tom Ruczynski

Accounting

Michelle Mitchell

Process Eng Mgr

Mark Foster

MaintenanceTechs

Janitor

Quality Manager

Tom Blair

MaterialsManagementDaniel Parker

Director of Program MgtJoe Vultaggio

SupervisorsCarol Dekin

David Shiver-Decker

PPAP CoordinatorMerrianne Robinson

Floor Inspectors

GP-12 Inspectors

Account Clerk / Receptionist

Ship/RcvgSupervisor

Kenny Reynolds

Shipping Clerk

Customer ServiceDonnelle Land

Warehouse

Group Leads

Operators

Plant ManagerRich Pitoniak

Vice President, Sales & Marketing

Joe Grippe

Program ManagerKent McJunkin

Program ManagerRob Pryomski

Process Tech’sDie Setters

Material Handlers

Management RepQuality System

Tom Blair

HR AdministratorCindy Simbandi




02/01/09 01/13/11 005

Rev: Updated Org Chart for Anderson

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(Section 14)

PROPER TOOLING- ANDERSON ORGANIZATIONAL CHART (14.6)

GENERAL MANAGER

Jim Billington

Shop Supervision

Jim BIllington

Machining Leader

Brian Smith

Core Manufacturing

John Walters

EDM

Real Time Programming

Mold Design

Core Manufacturing

E/C Engineering

Purchasing

Details

Assembly

Benching / Spotting

CNC Milling

CMM




12/22/08 01/13/11 001


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(Section 14)

PLASTICS GROUP ORGANIZATIONAL CHART (14.7)

ANDERSON

General ManagerKevin Bokros

Plastics GroupExecutive Vice President

Tom Ruczynski

Sales

Program Management

CROSWELL

General ManagerDoug Gangwer

Costing

CORPORATE

Director of Program ManagementJoe Vultaggio



02/01/09 Release

Rev: revising all organizational charts


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ENGINEERING (Section 15) 15.1 Preliminary / Intermediate Mold Design Phase PURPOSE This is a standard for documenting input information received on a concept & preliminary mold design as well as relaying the information for customer approval. SCOPE This is a Proper Tooling engineering standard that includes all internal and outsourced designs. RESPONSIBILITY The engineering supervisor/manager has the responsibility of ensuring that concept & preliminary designs are completed and reviewed using the supplied design input requirements. PROCEDURE Concept Design General The design lab leader / manager or the engineering supervisor/manager reviews the Project APQP Plan

Form 3.3, the three view drawings, customer supplied information, and any other information gathered at the kick off / pre kick off meeting (See Kick Off / Pre Kick Off Phase Section 3.6) in order to initiate the concept designs.

In general, the concept designs should consist of the following: Overall tool dimensions Three views showing the entire part geometry within the established block sizes Needed sections Mechanical concepts developed

Prior to beginning the preliminary designs, a concept meeting is held as required. At the discretion of executive management, the tool main block(s) may be ordered using the concept

designs without customer approval. Preliminary Design General Information gathered from the Project APQP Plan Form 3.3, the kick off / pre kick off meeting, and the

concept review meeting should be forwarded to the designer prior to beginning the preliminary design phase.



Rev. Added Intermediate Level Design information & updated Internal Approval.

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ENGINEERING (Section 15) 15.1 Preliminary Mold Design Phase (continued) The Preliminary Mold Design Checklist Form 15.1 is used by the designer as a guide prior to submitting

the design for internal preliminary approval. Intermediate Level Design General An intermediate level design should consist of all information as contained on the Mold Design Checklist

Form 15.1 in the Intermediate Level Section.

The customer is responsible for making the decision whether an intermediate level design will be required, or if the design should bypass the intermediate level phase and be taken directly to the final design phase.

The Preliminary Mold Design Checklist Form 15.1 should be used by the designer as a guide prior to

submitting the intermediate level designs to the design leader for internal approval. Internal Approval Upon completion of the preliminary designs.

The designs and the Preliminary Mold Design Checklist Form 15.1 are forwarded to the design leader

for review. The designer is to review the designs for all information as outlined on the Preliminary Mold Design

Checklist Form 15.1. If modifications are necessary, the design leader is to forward the designs, the design checklist, and any

notes needed in order to make the appropriate modifications to the designer.

After the internal approval has been completed, a copy of the Preliminary Mold Design Checklist Form 15.1 signed by both the designer and designer leader is filed in the design folder.

Preliminary Design Customer Sign-Off Once the internal approval process is complete the designer is to complete a Blueprint/PDF Request

Form 15.2a. If not specified by the customer a PDF or the following prints should be produced: (2) sets for the customer The original prints should remain in the possession of the engineering department.

The design leader is responsible for sending the PDF or prints and a copy of the Tool Design Approval

Form 15.2b to the program manager. The program manager then forwards the PDF or prints along with the Tool Design Approval Form 15.2b to the customer.

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ENGINEERING (Section 15) 15.1 Preliminary Mold Design Phase (continued) After customer sign off, if changes are made that either alter from the original scope of the Project

APQP information or if the change/mark-up needs to be quoted as a cost impact to the tool/design, a Change Order Form 3.15 is written.

The original preliminary mold designs or PDF are to be folded and stored in the design folder, along with

any notes and/or changes the customer may have marked up and a copy of the signed Tool Design Approval Form 15.2b.

After all changes are made, the design coordinator is to release a PDF or (2) copies of the mold designs

and BOM to the manufacturing group, and an extra BOM to the purchasing department along with an 11x17 print of the Core Plan View, View Y, and an Eyebolt Sketch (if applicable).

RELATED DOCUMENTATION Form – Project APQP Plan 3.3 Form – Preliminary Mold Design Checklist 15.1 Form – Blueprint/PDF Request 15.2a Form – Tool Design Approval 15.2b Procedure – Kick Off / Pre Kick Off Phase Section 3.6 Level 1 – Design and Development Outputs Section 7.3.3 Level 1 – Design and Development Verification Section 7.3.5 Level 1 – Design and Development Validation Section 7.3.6

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ENGINEERING (Section 15) 15.2 Final Mold Design Phase PURPOSE This is a standard for documenting information contained in a final mold design as well as relaying the information for customer approval. SCOPE This is a Proper Tooling engineering standard that includes all internal and outsourced designs. RESPONSIBILITY The engineering supervisor/manager has the responsibility of ensuring the final mold designs and the standards are being adhered to. PROCEDURE Final Design General Information gathered from the Kick Off / Pre Kick Off Phase Section 3.6 and the Preliminary Mold

Design Phase Section 15.1 should be forwarded to the designer prior to beginning the final design phase.

It is the responsibility of the design leader to ensure that all information is communicated to the

designer. The final Mold Design Checklist Form 15.2 should be used by the designer as a guide prior to submitting

the design for internal final design approval. Internal Approval Upon completion of the final mold designs, the designs are forwarded to the design leader. The design leader is to review the prints for all information as outlined on the Mold Design Checklist

Form 15.2. If modifications are necessary, the design leader is to forward the designs, the design checklist, and any

notes needed in order to make the appropriate modification to the designer. Upon completion of the design modifications, the checklist is signed off by the design leader, designer,

and filed in the design folder.



Rev: Removed Semi Final section, changed titles.

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ENGINEERING (Section 15) 15.2 Final Mold Design Phase Final Design Customer Sign Off Once the internal approval process is complete, the designer is to complete a Blueprint / PDF Request

Form 15.2a. If not specified by the customer a PDF or the following prints should be produced: (2) sets for the customer (3) sets for the manufacturing department The original prints should remain in the possession of the engineering department.

The Tool Design Approval Form 15.2b is then filled out by the designer and forwarded to the design

leader. The design leader is responsible for sending the prints and the Tool Design Approval Form 15.2b to the

program manager. The program manager then forwards the prints and Tool Design Approval Form 15.2b to the customer.

After the customer has signed and returned the Tool Design Approval Form 15.2b, the design leader is

to take (3) sets of final mold designs to the manufacturing area. The Tool Design Approval Form 15.2b is to be returned to the designer and filed in the design folder. The design leader is to take the stocklist to the purchasing department for the material and component

order. RELATED DOCUMENTATION Form – Mold Design Checklist 15.2 Form – Blueprint / PDF Request 15.2a Form – Tool Design Approval 15.2b Procedure – Kick Off / Pre Kick Off Phase Section 3.6 Procedure – Preliminary Mold Design Phase Section 15.1 Level 1 – Design and Development Outputs Section 7.3.3 Level 1 – Design and Development Verification Section 7.3.5 Level 1 – Design and Development Validation Section 7.3.6

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ENGINEERING (Section 15) 15.3 Design Outsourcing PURPOSE This is a standard for documenting all information that is used for design outsourcing. SCOPE This is a Proper Tooling engineering standard that includes all internal and outsourced designs. RESPONSIBILITY The design lab manager or engineering supervisor/manager has the responsibility of ensuring that the information being sent to the design outsource vendor is complete as well as ensuring that the information coming in house is received and documented properly. PROCEDURE Request For Quotation The design coordinator is to complete the Design Outsourcing Checklist Form 15.3 and mark the

request for quotation column. All information known is to be completed such as: General Tool Build Description Customer Molding Requirements Preliminary Mold Design Requirements Surfacing Requirements Final Mold Design Requirements Data Information Timing Requirements

Any supplemental information such as prints, rapid prototype models, or parts should also be forwarded

to the vendor. Job Kick Off After the costs have been agreed upon, a Purchase Requisition Form 8.1 is to be completed by the

design coordinator or the engineering supervisor/manager or the design lab manager.



Rev: Design lab manager shares responsibility with engineering supervisor/manager

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ENGINEERING (Section 15) 15.3 Design Outsourcing After approval of the Purchase Requisition Form 8.1 per the Purchasing Guidelines Section 8., a

purchase order number is assigned and sent to the vendor with the Design Outsourcing Checklist Form 15.3, which becomes the actual kick off date.

The Design Outsourcing Checklist Form 15.3 is to be marked for job kick off and all information is to be

complete. This form replaces the Subcontractor Work Specifications Form 8.2b for design outsourcing ONLY. Tracking Outsourced Jobs It is the responsibility of the design coordinator or the design leader to relay information to and from the

outsource vendor. All timing should be reported to the design leader on a weekly basis. The design leader is responsible for validating the functional aspects of the tool. RELATED DOCUMENTATION Form – Purchase Requisition 8.1 Form – Subcontractor Work Specifications 8.2b Form – Design Outsourcing Checklist 15.3 Procedure – Purchasing Guidelines Section 8.1 Level 1 – Design and Development Planning Section 7.3.1

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ENGINEERING (Section 15) 15.4 Moldflow Analysis Phase PURPOSE This procedure establishes a system to ensure that all Moldflow studies are documented, reviewed, and approved by the appropriate associates before Proper Tooling design / engineering proceeds with manifold development. SCOPE This procedure is utilized throughout program management and design / engineering. RESPONSIBILITY It is the overall responsibility of the program manager and designer to adhere to this procedure. PROCEDURE A program manager or sales associate requests a Moldflow Analysis through submission of a Change

Order Form 3.15 or Project APQP Plan Form 3.3 at kick off. A preliminary Moldflow Analysis is run to determine date locations and process capabilities. The preliminary Moldflow results are then submitted to program management with a Moldflow Approval

Form 15.4. The program manager will submit the preliminary results to the customer with the Moldflow Approval

Form 15.4. The customer has 3 days to approve the results and resubmit the Moldflow Approval Form 15.4 to

program management. After customer sign off, if changes are made that either alter from the original scope of the Project

APQP Plan Form 3.3 information or if the change / mark up needs to be quoted as a cost impact to the tool / design, a Change Order Form 3.15 is written.

Program management will then forward the signed approval to the design / engineering department. A final Moldflow Analysis is run to establish the manifold and/or runner design. The final Moldflow results are then submitted to program management with the Moldflow Approval Form

15.4.

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ENGINEERING (Section 15) 15.4 Moldflow Analysis Phase (continued) The program manager will then submit the final results to the customer with the Moldflow Approval Form

15.4. The customer will have 3 days to approve the results and resubmit the Moldflow Approval Form 15.4 to

program management. Program management then notifies the design department of the final approved study. RELATED DOCUMENTATION Form – Project APQP Plan 3.3 Form – Change Order Form 3.15 Form – Moldflow Approval 15.4 Level 1 – Design and Development Planning Section 7.3.1 Level 1 – Design and Development Inputs Section 7.3.2 LEVEL 3 Engineering Manual - Moldflow Requirements / Procedures 3.6

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Transcript of Level 2 Procedures Manual