Final Revision by jared czerew

13870 E. 11 MILE Rd WARREN, MI 48089

LEVEL 2 PROCEDURES MANUAL

‘11

TABLE OF CONTENTS HUMAN RESOURCES

1.0

TRAINING AND DEVELOPMENT CORPORATE QUALITY AND DEVELOPMENT

1.1 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

2.5

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

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

PRODUCT IDENTIFICATION

6.3

CONTINGENCY PLAN FOR IN PROCESS WORK

6.4

SERVICING

6.5

AEROSPACE SERVICING

6.5.5

CONTENTS cont… ASSOCIATE TRAVEL AND EXPENDITURE PROCEDURES

6.6

SERVICE GROUP ASSOCIATION GUIDELINE

6.7

WELDING

6.8

FIRST ARTICLE INSPECTION

6.9

INTERMEDIATE AND FINAL INSPECTION

6.10

ALL DEPARTMENTS

7.0

RECORD RETENTION AND CONTROL

7.1

DOCUMENT CONTROL

7.2

PURCHASING

8.0

PURCHASING GUIDELINES

8.1

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

10.1.5

DESIGN FMEA

10.2

PROCESS FMEA

10.3

FACILITIES MANAGEMENT

11.0

CONTENTS cont… 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

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

CONTENTS cont…

ENGINEERING

15.0

PRELIMINARY MOLD DESIGN PHASE

15.1

FINAL MOLD DESIGN PHASE

15.2

DESIGN OUTSOURCING

15.3

MOLDFLOW ANALYSIS PHASE

15.4

CONTACTS CORPORATE QUALITY AND DEVELOPMENT (PATTI O’BRIEN)

pobrien@propergroupintl.com

HUMAN RESOURCES

hr@propergroupintl.com

WEBSITES www.propergroupintl.com www.propertooling.com 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 hu man r esources depar tment i s responsible f or e stablishing and m appropriate training records.

aintaining the

The depar tment su pervisors and m anagers are r esponsible f or det ermining asso ciate t raining needs and ensu ring t hat onl y per sonnel w ho ar e su itably qualified p erform t asks requiring acquired skill. PROCEDURE 

All t asks within P roper G roup I nternational, w hich ar e adv ersely af fected by the l ack of acquired skill, w ill be identified and m ade the s ubject o f a job descr iption t hat reflects the extent and evidence of skill required.



All associates will receive appropriate training before and during carrying out manufacturing or testing operations.



Training pr ograms are d evised t o ensu re co mplete familiarity with al l r equirements of t he process.



Records will be m aintained o f t raining t hat i s given and t he co mpletion o f t raining w ill be subject to review at the end of training.



Periodic review of t raining r equirements will b e m ade t o e nsure that t raining 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.

PROCEDURES MANUAL HUMAN RESOURCES (Section 1) 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 pol icies 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 est ablished 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 asso ciate t akes an out side co urse r elated t o t heir cu rrent j ob f unction 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 r eimbursement pr ocedures are out lined i n t he asso ciate handboo k that each new associate receives upon employment.



The associate is responsible f or filling ou t t he Training Lo g Fo rm 1. 1n w ith al l c lass and training i nformation. The human resource department is responsible f or ensu ring t hat each associate who turns in a tuition reimbursement form, has also turned in the Training Log For m 1. 1b. T he h uman r esource depar tment w ill t hen l og i n t he i nformation on t he Training Log.

PROCEDURES MANUAL HUMAN RESOURCES (Section 1) 1.1 Training & Development

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 o f t he asso ciate upon appr oval of t heir su pervisor. S upervisors may al so se nd 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 Lo g Fo rm 1.1b t o the hu man r esource depar tment, w ho will t hen l og i n t he information on the Training Log.

In House Training Sessions 

When a nu mber o f as sociates will benef it from a job-related co urse, ei ther so meone 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.

PROCEDURES MANUAL HUMAN RESOURCES (Section 1) 1.1 Training & Development

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 f or i ncluding t he Training Lo g For m 1 .1.b w ith t he 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 t his 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 f or l ogging i n al l information on t he Training Log.



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

Evaluation of Training 

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

PROCEDURES MANUAL HUMAN RESOURCES (Section 1) 1.1 Training & Development (Cont..) 

The hu man r esource d epartment w ill det ermine i f a Training E valuation For m 1. 1a i s 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 r eturn 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 r eceive an em ail from t he hum an resources department on a monthly basi s informing t hem o f w hich asso ciates are due a pe rformance r eview t hat month.  A chart tracking the percentage of reviews submitted on-time and percentage of reviews completed will be included in this email.



Associate Tr aining hou rs are t racked t o se e i f the co mpany’s goals for training a re bei ng 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)

PROCEDURES MANUAL HUMAN RESOURCES (Section 1) 1.1 Training & Development

RELATED DOCUMENTATION [appendix] 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

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 de fines t he sco pe for pl ant m eetings, topic, objectives, i ntervals, 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 [appendix] 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

PROCEDURES MANUAL CORPORATE QUALITY AND DEVELOPMENT (Section 2) 2.2

Internal Quality Audit

PURPOSE To ev aluate and v erify w hether q uality act ivities and r elated results c omply with t he q uality 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 per formed o n al l r equirements at a m inimum o f twice a year. T he Q uality Management Internal Audit Schedule Form 2.2a is used as the guideline for when the audits take place.



The audi tors do not ha ve an y di rect asso ciation or r esponsibility f or t he ar ea t hey ar e auditing.



New po licies or pr ocedures are no t audi ted for a m inimum o f four w eeks after t he si gned 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 R AB, AIAG, or other recognized quality system auditor or lead auditor certification. ASQ Certified Quality Auditor (CQA) is also acceptable. Issuing Dept.

Corporate Quality & Development

Officer

Established 09/05/00

Revision 03/06/09

Rev: Detailed information for CARs and planning internal audits.

Rev # 006

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 audi tor m ust co ntact t he depar tment m anager t o sch edule and p erform t he i nternal 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 oper ation 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 A udit R eport Fo rm 2.2c is presented a t t he m eeting al ong w ith t he C orrective A ction 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

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 o r i nternally. (Reference P rocedure – Corrective A ction R eporting & R esponse Section 3.18)



When there i s a C orrective Action R eport For m 2.2b w ritten, a C AR num ber i s 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 dat e or elevate CAR to the next management level.



If the CAR was elevated to the next level of m anagement the CAR m ust 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. I f i t i s not, the C AR i s sent b ack to t he asso ciate an d t heir i mmediate supervisor to review for improvement. T he 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 co nfirm 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.

PROCEDURES MANUAL 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. T his 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 i t i s t ime for an audi t, the management r epresentative w ill co mplete the audi t 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 f lagged 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.

PROCEDURES MANUAL CORPORATE QUALITY AND DEVELOPMENT (Section 2) 2.2

Internal Quality Audit

RELATED DOCUMENTATION [appendix] 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

PROCEDURES MANUAL CORPORATE QUALITY AND DEVELOPMENT (Section 2) 2.3

Continuous Improvement

PURPOSE Continuous improvement is a brainstorming activity for Proper Group International. Continuous improvements are m ade i n al l ar eas of t he co mpany f rom ad ministrative t hrough t he manufacturing process to improve quality, timing, cost and customer satisfaction. SCOPE This applies to all areas of Proper Group International. RESPONSIBILITY The p resident has the overall r esponsibility f or r eviewing t he co ntinuous improvement i deas. 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 co ntinuous improvement i deas that a re i mplemented may r equire s tatistical 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 t he Continuous Improvement Management Meeting Open Issues Form 3.6c. Issuing Dept.

Corporate Quality & Development

Officer

Established 01/01/01

Revision 02/01/09

Rev # 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

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 [appendix] 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

PROCEDURES MANUAL CORPORATE QUALITY AND DEVELOPMENT (Section 2) 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 r eview pr ocess covers all appl icable A S 91 00 Q uality S ystem el ements affecting P roper Group International. RESPONSIBILITY The management representative is responsible for g athering all referenced related documents and conducting a r eview of these items and any other pertinent information. The lead auditors are r esponsible for sch eduling and co nducting a r eview of t he i nternal audi ts that hav e been completed. PROCEDURE 

Officers of the Company, general managers, department managers, lead auditors, and t he management representative attend this meeting.



The minutes o f t hese meetings are docu mented i n t he M anagement M eeting R eview Minutes Form 2.4 and filed in the corporate development department along with the internal audit results. They are also saved electronically.



A docu mented management review of P roper’s Quality M anagement S ystem and i nternal audit r esults is conducted and reported on a fter the r egularly sch eduled i nternal audi ts (twice a year) by Proper’s management.



All appl icable pr ocesses of the quality m anagement system a re add ressed dur ing 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

PROCEDURES MANUAL CORPORATE QUALITY AND DEVELOPMENT (Section 2) 2.4

Management Review Meeting of the Quality System

RELATED DOCUMENTATION [appendix] 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

PROCEDURES MANUAL 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, pl ease make s ure t he following appea rs somewhere on each page o f each sketch submitted:

Issuing Dept.

Corporate Quality & Development

Officer

Established 03/01/03

Revision 01/19/09

Rev: Changed company name and logo

Rev # 002

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 r equest 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 pr ocessed, the account manager will contact the customer in writing to inform them of the reason that the quotation will not be processed.



A co py of t his notice a long w ith t he o riginal i nformation received from t he cu stomer i s forwarded to the estimating administrative associate to be logged in as “No Quote” and filed.



If the quotation w ill be processed, t he quotation pack age i s assembled by t he acco unt 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 pac kage i s then forwarded t o the est imating ad ministrative asso ciate t o b e 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. Issuing Dept.

Sales / Program Management

Officer

Established 09/05/00

Revision 03/06/09

Rev # 003

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

PROCEDURES MANUAL SALES AND PROGRAM MANAGEMENT (SECTION 3) 3.1 Request For Quotation (continued) 

If for any r eason t he quotation ca nnot be co mpleted i n t he est imating depar tment, t he account manager will be notified.



The account manager will contact the customer in writing to notify them that the quotation cannot be pr ocessed 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 co py of the notice to the cu stomer w ill be f iled with t he q uote pac kage and t he q uote w ill be logged i n 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 r eason t he quotation ca nnot be co mpleted i n t he est imating depar tment, t he account manager will be notified.



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



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

PROCEDURES MANUAL SALES AND PROGRAM MANAGEMENT (SECTION 3) 3.2

New Customer Approval

PURPOSE To est ablish a pr ocedure for appr oving and addi ng new cu stomers into P roper G roup 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 t he c redit l imit i s over $10, 000, a D & B R eport m ust be at tached t o t he C redit Application.



The N ew C ustomer A pproval For m 3. 2 and t he P roper 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 cu stomer i s put i nto our sy stem and has a cu stomer nu mber, t he am ount o f t he 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. Issuing Dept.

Officer

Sales / Program Management

Established 09/05/00

Revision 11/21/08

Rev: Adjusted company name

Rev # 003

PROCEDURES MANUAL SALES AND PROGRAM MANAGEMENT (SECTION 3) 3.2

New Customer Approval

RELATED DOCUMENTATION [appendix] Form – New Customer Approval 3.2 Form – Credit Application 3.2a Form - Credit Limit Adjustment Request 3.2b Level 1 – Planning of Product Realization Section 7.1 Procedure-Kick Off/Pre Kick Off Phase 3.6 Procedure- Prototype Kick Offf Phase 3.6

PROCEDURES MANUAL 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, di stribute, and maintain t he P roject A PQP P lan For m 3 .3 a fter t he pr oject 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 ot her non st andard se rvices related t o feasibility su pport, w arranty, onsi te 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 pr oject 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 m issing i nformation i n t he pl astic part, molding machine, t ooling 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 A PQP r evision l evel on pag e 1 , and l og the A PQP r evision l evel i n t he revision log as the project kick off / Change Order 001.  Proceed w ith t he K ick O ff / P re K ick O ff P hase S ection 3. 6 o f t he Proper G roup International Procedure Manual.

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 pr oject scope ch anges throughout t he life of the project, the P roject A PQP P lan For m 3. 3 i s to b e updat ed and di stributed w ith a C hange Order For m 3.15. This is only r equired when t he change affects the information on the APQP.

RELATED DOCUMENTATION [appendix] 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

PROCEDURES MANUAL 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 r equirements, v erifying t hat the el ements of the p roposal e ffort hav e been m utually 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 t he purchase order stamp. ( The purchase order stamp includes the l ine sp aces to i ndicate t he j ob n umber, quote nu mber, and P roper G roup 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 sa les associate or program m anager w ill c oordinate any r equired 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 Issuing Dept.

Sales / Program Management

Officer

Established 09/05/00

Revision 07/15/09

Rev # 006

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

PROCEDURES MANUAL SALES AND PROGRAM MANAGEMENT (SECTION 3) 3.4

Receipt of Purchase Order (continued)



If there are any differences between the purchase order and w hat was agreed to, the sales associate co ntacts the c ustomer t o r esolve t he i ssue(s) p rior t o acce ptance of the or der. Depending on the resolution t o the i ssue(s), a new pur chase or der i s received or t he 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 pr ogram management (for the master file and invoicing).



If al l docu ments are co rrect a C hange Order Fo rm 3 .15 / 3. 15.5 i s written t o ex ecute t he 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 w hat was agreed to, the sales associate contacts the customer to resolve the issue prior to acceptance of the order.



Once the pu rchase o rder i s verified as correct, t he sa les asso ciate fills out the pu rchase order stamp listing the job number, quote number, and their approval signature.



The pu rchase or der i s forwarded t o t he ad ministrative asso ciate o f pr ogram 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 [appendix] 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

PROCEDURES MANUAL SALES AND PROGRAM MANAGEMENT (SECTION 3) 3.5

New Project Identification System

PURPOSE To i dentify a pr oject nu mber for al l pr ototype / production / en gineering / an d 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 asso ciate r equiring a pr oject i dentification num ber for r epair w ork o r eng ineering changes ( tools not bui lt by P roper) must co ntact t he adm inistrative as sociate o f pr ogram management for a new project number.



Project numbers are designated as an 10000 series number for Warren, a 21000 se ries 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 ap proved 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 co py of the purchase order or the customer signed quotation or award letter or email authorization. (per the Kick Off / P re 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 pr oject number there must be a co py 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). Issuing Dept.

Sales / Program Management

Officer

Established 09/05/00

Revision 01/05/09

Rev # 006

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

PROCEDURES MANUAL 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 [appendix] 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

PROCEDURES MANUAL SALES AND PROGRAM MANAGEMENT (SECTION 3) 3.6

Kick Off / Pre Kick Off Phase

PURPOSE This procedure provides all key design, manufacturing and p rogram management departments with complete background information needed for construction of molds / tools. SCOPE Applies to al l pr oduction and C lass 1 & 2 pr ototype m olds and A erospace co mponents manufactured by Proper Group International. RESPONSIBILITY The sales department has the overall responsibility for initiating this procedure for Proper Tooling and the manufacturing en gineer for P roper A erospace and completing al l docu ments 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. Initiation of Meeting 

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

Issuing Dept.

Sales / Program Management

Officer

Established 09/05/00

Revision 12/15/08

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

Rev # 009

PROCEDURES MANUAL 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 w ill 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 t hen initiate the kick o ff / pre kick off meeting and w ill 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. Topics of Discussion    

Discuss APQP plan (customer input should be available). Complete review of all documents brought to the meeting. General outline of what the company is manufacturing. Review T iming and resource pl an t o assu re r esources have been i dentified to su pport al l operations and meet the delivery commitment.

PROCEDURES MANUAL 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. Outcome 

The following paperwork will be completed upon the outcome of this meeting:  Project A PQP P lan For m 3. 3 / 3. 5 – updated w ith any ch anges resulting from t he 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 t o release data and f ormally kick off t he project.. D istribution f or t his change order is indicated in the Distribution List.

Additional Sales Department Responsibilities 

The Proper Program Management Manual for the specific project will be created.

Obsolete Drawings New Customer Approval Full Size Plots Original Quote Package x x

Director of Operations

Director of Eng / Mfg

Core Manufacturing Group

Project File

x x

Design

Scheduling Associate

Program Manager

Quality

Data Management

Change Order 001 Distribution Project APQP Plan Data Request Form Open Issues Timeline 

Sales

Mold Leader

Foreman

Distribution List (Hard Copy)

x x x x x

The forms in green are available on the system for all to review.

x x x x

x x x x x

X X

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

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

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 en gineering depa rtment has the ov erall r esponsibility f or i nitiation and co ntent o f 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 i ntention of this meeting i s to r eview t he initial co ncept desi gns for t he m old t o be manufactured.



Through t his review of t he co ncept desi gn, completion of the following i nformation w ill 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 di rection f or the desi gn depar tment t o finalize pr eliminary designs for cu stomer submission.  Review capacity / backlog issues regarding the project. Issuing Dept.

Sales / Program Management

Officer

Established 09/05/00

Revision 12/15/08

Rev # 006

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

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 f easibility i ssues resulting i n pr oject ch anges. ( 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 ar e addi tions or ch anges to t he Open Issues Form 3. 6c or t imelines, t he desi gn 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

3.8

PROCEDURES MANUAL SALES AND PROGRAM MANAGEMENT (SECTION 3) 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 Issuing Dept.

Sales / Program Management

Officer

Established 09/05/00

Revision 12/15/08

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

Rev # 008

PROCEDURES MANUAL SALES AND PROGRAM MANAGEMENT (SECTION 3) 3.8 Manufacturing Process Plan Phase  Through t his review of t he m anufacturing pr ocess plan m eeting, t he following i nformation 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 [appendix] 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

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 w ill verify t he r evision l evels of t he cu stomer dr awing docu mentation and/ or di gital 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 E ngineering sh all m aintain Work Order R evisions as required t o i ncorporate 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 V erification M ethod for pu rchased pr oduct will be def ined on t he Work Order R outer Form 3.8.5..  If ce rtification i s required, t hey w ill be co mpared t o t he cu stomer sp ecification and/ or desired standards.  The review will verify that the elements of the certification match the specifications. Issuing Dept.

Sales / Program Management

Officer:

Established 12/15/08

Revision 07/07/09

Rev # 003

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

PROCEDURES MANUAL SALES AND PROGRAM MANAGEMENT (SECTION 3)  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 i dentifications will be not ed on t he Work Order R outer F orm 3 .8.85 i n t he manufacturing router sequence when they apply.  Validation / Inspection Criteria will be specified on t he Work Order Router Form 3.8.5 per the customer s tandards, de sign s tandards, pu rchase or der requirements a nd/or as w e deem necessary.  The cr iteria sh ould i dentify t he sp ecifications, t he i nspection m ethod, frequency o f 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 m ay i nclude product i dentification or serialization as identified by t he cu stomer 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 num bers can n ot be r eassigned, ev en i f a pr oduct i s scrapped dur ing t he 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 doc umented on the Work Order Router Form 3.8.5 with the initials of the person making the change.

Manufacturing Work Order R outers Form 3 .8.5 a fter t he Fi rst A rticle may be ch anged for part quantities and delivery only by the manufacturing engineer and/or supervisor. 



These ch anges must b e docu mented on t he Work Order R outer For m 3. 8.5 w ith t he 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.

PROCEDURES MANUAL SALES AND PROGRAM MANAGEMENT (SECTION 3) 

3.8.5

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. 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 [appendix] 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

PROCEDURES MANUAL SALES AND PROGRAM MANAGEMENT (SECTION 3) 3.9 Customer Property PURPOSE This procedure pr ovides specific instructions for t he ca re w ith cu stomer pr operty while i t i s 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 cu stomer dat a, el ectronic or i n paper format, a re l ogged i nto the d ata management department. Issuing Dept.

Sales / Program Management

Officer

Established 03/30/09

Revision

Rev: New Procedure

Rev #

Release

PROCEDURES MANUAL SALES AND PROGRAM MANAGEMENT (SECTION 3) Ongoing Control 

All cu stomer dat a i s stored i n t he P roper Group I nternational da ta servers under t he customer name, month, and year.



This data i s r etained i n a q uarantined sy stem n ot r eleased t o P roper Group I nternational associates.



Customer st andards are l ogged i n at t he en gineering depar tment w ith only ( 2) co ntrolled 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. manager will give direction for the appropriate location to store the product.

The program



If changes to the product are required, a C hange 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 P roper Group International facility must be i nspected 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. manager will give direction for the appropriate location to store the product.

The program

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 [appendix] 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

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) Issuing Dept. Officer Established Revision  Mold Leader (Manufacturing Supervisor) Sales / Program 09/05/00 10/01/06  Quality (Quality Technician) Management  Process Engineer (Process Technician) Rev: Revised for new ISO standard. 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.

Rev # 004

PROCEDURES MANUAL SALES AND PROGRAM MANAGEMENT (SECTION 3)  3.10

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

x x x

RELATED DOCUMENTATION [appendix] 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

x x x

Manufacturing Supervisor

Engineering

x x

Program Manager

x x

General Manager Manufacturing

Mold Leader

Open Issues Change Order Mold Tryout Open Issues

Process Engineer

Quality

Distribution List

x x

PROCEDURES MANUAL 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 al l pr oduction m olds / tools and r elated pr oduct manufactured by t he P ME 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 sch eduling depar tment w ill se nd a m eeting not ice t o t he following asso ciates 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 f inancial and del ivery information i s provided by program management. Fi nancial 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. Issuing Dept.

Sales / Program Management

Officer

Established 09/05/00

Revision 10/01/06

Rev: Revised for new ISO standard.

Rev # 005

PROCEDURES MANUAL SALES AND PROGRAM MANAGEMENT (SECTION 3) 3.11

Post Shipment Phase

Outcome   

All Open I ssues Form 3.6c that ar e det ermined t o dr ive ch anges to P ME pr ocesses, procedures, and standards are added to the Open Issues Form 3.6c. Customer sp ecific r equirements that are no t co vered i n t he or iginal q uoting process ar e forwarded t o t he est imating depar tment to ensu re t hey ar e par t of t he st andards used for further quoting. Complete Project O verview For m 3. 11 is submitted t o t he P resident at t he t ime o f the operations meeting for discussion and possible additional action.

Distribution of Completed Project Overview Form 3.11  

Program Management File President

RELATED DOCUMENTATION [appendix] Form- Open Issues 3.6 Form-Project Overview 3.11 Form- Change Order 3.15 Procedure- Operation 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

PROCEDURES MANUAL SALES AND PROGRAM MANAGEMENT (SECTION 3) 3.12

Prototype Kick Off

PURPOSE This procedure p rovides all k ey m anufacturing depa rtments with co mplete bac kground 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 t his 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.

Issuing Dept.

Sales / Program Management

Officer

Established 09/05/00

Revision 12/15/08

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

Rev # 007

PROCEDURES MANUAL SALES AND PROGRAM MANAGEMENT (SECTION 3) 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 t he Change O rder For m 3. 15 number 001 t o r elease dat a and f ormally k ick t he project off.

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

X X X X

X X X

Design

Project File

Sales

General Manage r – Proper Technol ogies

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

X X X X X

X X

PROCEDURES MANUAL 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.

PROCEDURES MANUAL 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 [appendix] 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

PROCEDURES MANUAL 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 ch arts are av ailable f or r eview 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

Issuing Dept.

Sales / Program Management

Officer

Established 09/05/00

Revision 12/15/08

Rev # 007

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

PROCEDURES MANUAL SALES AND PROGRAM MANAGEMENT (SECTION 3) 3.13

Project Scheduling Meeting



Scheduling m eeting not es are r ecorded and di stributed to al l nece ssary per sonnel which records/lists all problem concerns, corrective action and nece ssary follow-up. T hese notes are published on the Proper Group International Job Forecast.



The ad ministrative asso ciate o f pr ogram m anagement keeps the master r ecords from the Proper Group International Job Forecast / Notes.



The general managers have t he r esponsibility and co ntrol t o pr event further pr ocessing, delivery or i nstallment o f non conforming p roducts or tooling un til the de ficiency or unsatisfactory condition has been corrected.

RELATED DOCUMENTATION [appendix] 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

PROCEDURES MANUAL 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 pr ocedure i s used for new pr oduction m olds and C lass 1 through C lass 3 prototypes: Initiation of a New Project 

During t he kick off phas e o f a new pr oject, a t imeline i n t he P roper Tooling’s Scheduling Capacity System is established.  The a ccount m anager i n ch arge o f the p roject i s responsible to ensu re the t imeline i s 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 pr ogram m anager i s responsible t o pr ovide al l updat es for t he cu stomer t imeline by Monday morning each week. Issuing Dept.

Sales / Program Management

Officer

Established 09/05/00

Revision 12/15/08

Rev # 004

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

PROCEDURES MANUAL SALES AND PROGRAM MANAGEMENT (SECTION 3) 3.14

Timelines



Customer distribution will be on Monday of each week unless there is a holiday, which wil l then be the next business day.



Distribution w ill be by requirements.

primarily em ail, f ax or i nternet dependen t o n t he cu stomer’s

RELATED DOCUMENTATION [appendix] 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

PROCEDURES MANUAL SALES AND PROGRAM MANAGEMENT (SECTION 3) 3.15

Change Orders

PURPOSE This is a co mpany w ide pr ocedure to docu ment and maintain a record of any ch anges 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 i s the r esponsibility of t he pr ogram m anager t o ov ersee any act ivities of ch ange 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. T he C hange O rder For m 3. 15 m ust l ist t he j ob num ber a nd su ffix, del ivery dates, data dates, and quotation number, if applicable.



Change or ders for ch anges or r epairs that ex ceed 2 w eeks or ch ange / est ablish 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) Issuing Dept.

Sales / Program Management

Officer

Established 09/05/00

Revision 03/06/09

Rev: Now accept written form of authorization.

Rev # 012

PROCEDURES MANUAL 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, s ketches, C AD scr een dum ps, and any addi tional information t hat m ay hel p 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

PROCEDURES MANUAL SALES AND PROGRAM MANAGEMENT (SECTION 3) 3.15

Change Orders (continued)



The customer m ust i ssue a pur chase o rder num ber, sign t he ap proved eng ineering 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 obt ained prior to the mold leaving the facility.



The w hite co py of the Change Order For m 3. 15 al ong w ith a si gned quotation, pu rchase 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 t he co mpletion o f t he t ime an d m aterial w ork, 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 acce pted by t he customer and r eturned, or di spatched technicians correct a defect in the product.  Completion / Finalization – molds that are not completed and acce pted 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 al so b e use d i n pl ace o f Warranty w hen t he f ailure w as 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 so me ca ses the ch ange or der may i nvolve “ chargeable i tems” and “ non chargeable i tems”. I n t his case, each i tem on t he ch ange or der i s marked for t he appropriate status.

NOTE: When a “ non p erformance o r w arranty” ch ange or der i s issued, t he pr ogram manager m ust i nclude the es timated hour s and t he e stimated ou tside se rvice 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.

 

PROCEDURES MANUAL 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 at tached 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 [appendix] 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

PROCEDURES MANUAL SALES AND PROGRAM MANAGEMENT (SECTION 3) RELATED DOCUMENTATION (continued) Procedure – In Process Inspection Section 6.1 Procedure – Incoming / I n P rocess Components & M aterial I nspection & N on C onformity 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

PROCEDURES MANUAL 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 eng ineering standard for de fining t he st eps involved i n pr oduct / t ooling feasibility prior to releasing the data to the manufacturing groups. RESPONSIBILITY The associate supervisor of engineering and program management has the r esponsibility 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 t ooling i s such a w ay t hat t he d esign and i ntegrity o f t he t ool al low f or t he manufacturing of product that will meet all customer or internally driven standards. Advanced E ngineering / D esign Lab – the st udy of pr oduct and t ooling co ncerns prior t o t he releasing data to the design and manufacturing groups. PROCEDURE Following i s the pr ocedures and descriptions for f illing out the Tool ing Feasi bility 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 st udy i s requested pr ior t o r eceiving a P roject A PQP 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.

Sales / Program Management

Officer

Established 09/05/00

Revision 01/12/09

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

Rev # 003

PROCEDURES MANUAL 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. T he l ine of dr aw and par ting l ines from cu stomer’s data w ill be use d 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. A ny 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 asso ciate assi gned t o t he Tooling Fea sibility S tudy For m 3 .16 must si gn i t 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.

PROCEDURES MANUAL SALES AND PROGRAM MANAGEMENT (SECTION 3) 3.16

Tooling Feasibility Study

Outcome 

Program m anagement i s responsible to co ordinate w ith t he cu stomer t o cl ose out al l feasibility i ssues, al l par t dev iations, and enhan cements outlined i n t he Tooling Fea sibility Form 3.16.



The Tooling Feasibility Study Form 3.16 and all attachments will be maintained in the master engineering job folder.

RELATED DOCUMENTATION [appendix] 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

PROCEDURES MANUAL 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 & dev elopment ass ociate i s responsible f or maintaining the docu ments for customer satisfaction. PROCEDURE 

Within 60 days of a new customer’s first new tool T1, a Customer S urvey Form 3.17 i s 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 al l t he i nformation and f ollow-up i nformation ( if any ) i s satisfactory, t he C ustomer Survey For m 3. 17 i s forwarded t o t he ex ecutive adm inistrative asso ciate w ith al l t he pertinent information listed on this form. Issuing Dept.

Sales / Program Management

Officer

Established 09/05/00

Revision 07/07/09

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

Rev # 005

PROCEDURES MANUAL 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 co mpletion o f al l s urveys, t he C ustomer S urvey S ummary For m 3 .17a i s completely filled out and given to the Officers of the Company and the general managers.

RELATED DOCUMENTATION [appendix] 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

PROCEDURES MANUAL 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 p rocedure descr ibes the cu stomer complaint and i ssues corrective act ion t o r esolve 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 su ch as dimensional, accu racy’s and/or co smetic 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 act ion w ith t he m anufacturing supervisor/manager and t he mold leader r egarding w hat co rrective act ions are ne cessary and w hat co rrections 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 r equested 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 t o do an 8D C oncern A nalysis Report For m 3. 19 due t o si milarities of ot her conditions, an 8D i s completed. (Reference P rocedure – 8-Discipline P roblem S olving Method Section 3.19)

Issuing Dept.

Sales / Program Management

Officer

Established 09/05/00

Revision 03/06/09

Rev: can use a CAR for customer complaints if necessary

Rev # 003

PROCEDURES MANUAL 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 t imely manner. This calendar is maintained by the corporate quality & development associate.

RELATED DOCUMENTATION [appendix] 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

PROCEDURES MANUAL 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 i mplemented and pr ocessed. 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 t eam w ill be f ormed and t he co ncern docu mented on t he 8D C oncern A nalysis Report Form 3.19.



Proper Group International - After the initial meeting with the team members, a copy will be r eturned to t he co rporate quality and dev elopment depa rtment for d ocumenting. T he 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 w ill be r ecorded and m onitored by co rporate quality & development.



Upon co mpletion o f steps D1 – D8 l isted bel ow, t he 8D w ill be cl osed. The following w ill 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. Issuing Dept.

Sales / Program Management

Officer

Established 09/05/00

Revision 03/06/09

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

Rev # 006

PROCEDURES MANUAL SALES AND PROGRAM MANAGEMENT (SECTION 3) 3.19

8-Discipline Problem Solving Method (continued)

Listed below are steps D1 – D8. D1. FORM THE TE AM - In this first step, a group of people will be g iven time and aut hority to solve the problem and implement corrective actions. This group should have a desi gnated 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 pr oblem occu rred. I solate and v erify t he r oot ca use by t esting each pot ential ca use 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 C oncern A nalysis Report For m 3 .19 is not t urned i nto to co rporate quality & development by t he due dat e, the per son w ho w as issued t he 8D Report N umber i s contacted for an update.



If more time is needed and this is approved by a managing associate, the Due Date is revised and docu mented on t he 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.

PROCEDURES MANUAL SALES AND PROGRAM MANAGEMENT (SECTION 3) 

If the 8D C oncern A nalysis Report For m 3. 19 i s not received, t he as sociate’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 t he 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 [appendix] 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

PROCEDURES MANUAL SALES AND PROGRAM MANAGEMENT (SECTION 3) 3.20

Action Plans

PURPOSE To standardize the procedure for implementation of project action plans. SCOPE This procedure appl ies to se lect p roduction and pr ototype m olds produced by P roper G roup 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 pr ogram manager or depar tment l eader i dentifies a m old w hich i s behind t he 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

Issuing Dept.

Sales / Program Management

Officer

Established 09/05/01

Revision 01/14/09

Rev: Updated team members, omitted Form 3.20

Rev # 005

PROCEDURES MANUAL SALES AND PROGRAM MANAGEMENT (SECTION 3) 3.21

Tryout Scheduling / Pre Sampling Phase

PURPOSE This procedure i s a guideline f or sch eduling tryouts, de fine obj ectives, v erify al l m aterials necessary for initial mold sampling is present, and tracking tryout costs against jobs. SCOPE This procedure applies to Proper Tooling. RESPONSIBILITY It i s t he responsibility of pr ogram management and t he p rocess en gineering 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 addi tion, i f t he tryout i s to be run out side P roper, t he p rogram manager m ust ob tain 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. Issuing Dept.

Sales / Program Management

Officer

Established 03/26/01

Revision 02/01/09

Rev: Combined procedure 3.9 with 3.21.

Rev # 007

PROCEDURES MANUAL SALES AND PROGRAM MANAGEMENT (SECTION 3) 3.21

Tryout Scheduling

(continued)



A co py of the Request f or Tr yout Form 3.21 is f orwarded to t he t ryout department. T he tryout department will:  Retrieve and st ore t he raw m aterials from P roper’s material w arehouse ( 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 t he Open Issues Action P lan For m 3 .6, and t he p rocessing i nformation 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 [appendix] 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

PROCEDURES MANUAL SALES AND PROGRAM MANAGEMENT (SECTION 3) 3.22

Tryout Material Handling

PURPOSE This procedure i s a g uideline b y which Proper T ooling’s shipping & r eceiving depar tment w ill manage tryout materials inventory and track material usage and location. SCOPE This procedure applies to Proper Tooling. RESPONSIBILITY It i s the responsibility o f t he sh ipping & receiving depa rtment and the pr ocess engineering department for adherence to this procedure. PROCEDURE 

All pl astic resin and other t ryout materials are t o be r eceived t hrough t he sh ipping & 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 co py of t he t ag i s attached t o t he r aw m aterial. T he r aw m aterial i s then st ored at t he 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 an y 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 t he M aterials Inventory sp readsheet and r eturn any r emaining r aw m aterials to t he customer with the mold.



Once the materials are returned to the customer, it is removed form the Materials inventory spreadsheet. Issuing Dept.

Sales / Program Management

Officer

Established 03/26/01

Revision

Rev: Changed company name & logo

12/15/08

Rev # 003

PROCEDURES MANUAL SALES AND PROGRAM MANAGEMENT (SECTION 3) 3.22

Tryout Material Handling (Continued)

RELATED DOCUMENTATION [appendix] 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

PROCEDURES MANUAL 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 pr ogram manager for adherence to this procedure. PROCEDURE 

Upon r eceipt of t he Request For Tr yout For m 3.21, t he pr ocess engineering su pervisor schedules the t ryout. ( See T ryout S cheduling S ection 3. 21 o f t he P roper G roup International Procedures Manual for information on scheduling tryouts).



The Request Fo r Tryout For m 3.21 is placed on t he tryout scheduling boar d i n 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 t he t ryout, t he pr ogram m anager an d pr ocess engineer w ill co mplete t heir appropriate a reas of t he M old P erformance E valuation For m 12 .4c and Part P erformance Evaluation Form 12.4d.



Any open issues from these w ill t ransfer t o the O pen I ssues Action P lan For m 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 m aterial i s re-weighed and the remaining w eight i s w ritten o n t he P roduct Identification tag.



Any scrap parts from the tryout are discarded outside. Issuing Dept.

Sales / Program Management

Officer

Established 03/26/01

Revision 02/01/09

Rev: updated with new APQP information that is required.

Rev # 004

PROCEDURES MANUAL SALES AND PROGRAM MANAGEMENT (SECTION 3) 3.23



Tryout Instructions (continued)



The area around the press is then completely cleaned.



The Mold P erformance E valuation For m 12 .4 is filled out and forwarded t o t he administrative associate, for first tryout only unless otherwise requested. A copy is filed in the process engineer’s master job file.



The Request Fo r Tryout For m 3 .21, Open I ssues Action P lan For m 3. 6, and t he processing information from t he i njection m olding m achines are filed i n t he pr ocess engineering master job file.

The Project Overview Form 3.11 is updated with the date of the tryout.

RELATED DOCUMENTATION [appendix] 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

PROCEDURES MANUAL 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 pr ogram 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 m odel released, an ov erlay will be per formed by t he core manufacturing group o r program management.



The co re m anufacturing dat a su pport asso ciate or pr ogram management da ta su pport 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 t he “Additional C omments” se ction, i t i s noted as to w hat the r evision i s for each ar ea effected.



After t he as sociate has evaluated t he e ffect to the t ooling, t he asso ciate w ill est imate t he time required for each step of the change and en ter the days estimated on page two of the worksheet.



The as sociate then co mpletes the E ngineering Change Worksheet Fo rm 3. 25, and si gns 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. Issuing Dept.

Sales / Program Management

Officer

Established 08/09/06

Revision 01/19/09

Rev: Removed production related information on page 2.

Rev # 004

PROCEDURES MANUAL SALES AND PROGRAM MANAGEMENT (SECTION 3) 3.25 Engineering Change Worksheet 

If t he customer authorizes the quoted ch ange, t he ov erlays and t he E ngineering C hange Worksheet Form 3.25 will be attached and distributed with the Change Order Form 3.15.

RELATED DOCUMENTATION [appendix] 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

PROCEDURES MANUAL QUALITY (Section 4) 4.1

Control of Measuring & Test Equipment

PURPOSE This pr ocedure pr ovides s pecific i nstructions f or t he v erifications, c alibrations a nd t he m aintenance of measuring and t esting equipment to e nsure proper f unctioning and c ontinued accuracy, t hus ens uring 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 

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



The levels of calibration are:  Calibration – an i n h ouse equ ipment v erification to t he s tandards es tablished within t his procedure.  Calibration with a C ertificate – a v erification of t he ac curacy of equ ipment c onducted b y 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

Issuing Dept. Quality

Officer

Established 09/05/00

Revision 03/20/09

Rev # 008

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

PROCEDURES MANUAL 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 d epartment manufacturing as sociates t rained on t he us e of measuring equipment m ay 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 ar e pl aced on eq uipment / ha nd tools. T hese t ools ar e no t t o b e us ed f or f inal 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 i s t o b e c onsidered “ Reference O nly.” T his i s f or bot h c ompany owned an d as sociate o wned tools.



Any m easuring and t est equipment t hat is o ut of c alibration is t aken ou t of s ervice. T he o ut 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 i nspection, m easuring and t est e quipment r ecords w ill be m aintained t hrough t he us e 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.

PROCEDURES MANUAL 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 f ollowing c ompany a nd as sociate owned e quipment / t ools within t he quality department ar e 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 eq uipment us ed f or f inal verification will b e r ecorded a nd t racked as r equired per o ur s oftware 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.

PROCEDURES MANUAL 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 m eeting t he s pecifications i s t agged an d s ervice is c ompleted t o br ing t he 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, t he customer w ill be no tified a nd c onsulted with a ny c orrective actions t hat m ay n eed to be taken.

PROCEDURES MANUAL QUALITY (Section 4)

4.1

Control of Measuring & Test Equipment

RELATED DOCUMENTATION [appendix] 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

PROCEDURES MANUAL 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 co mplete G D&T par t pr int pr ovided no later t han t wo weeks after t ool k ick o ff. 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 Fi rst A rticle Inspection – all t olerances per cu stomer specifications.

PROCEDURES MANUAL QUALITY (Section 4) 4.2

General Tooling Tolerances & Specifications Feature

Plus or Minus Callout

GD & T Callout

Size

+/- .15

∅

XX.XX

*Location

+/- .15

⊕

0.15

HOLES +/- .15

SLOTS Size

Length

+/- .3

Width

+/- .15

Length

+/- .15

∅

XX.XX

+/- .15

XX.X

+/- .15

⊕

0.15

Size

+ .15 / - .0

∅

XX.XX

*Location

+/- .15

⊕

0.15

Size

+.0 / -.15

∅

XX.XX

*Location

+/-.15

⊕

0.15

*Location

Width

+/- .25

HEAT STAKE HOLES +.15/-.0 A

HEAT STAKES +.0/-.15 A

CLIP ATTACHMENT RIBS Size

+/-.15

*Location

+/-.15

⊕

0.15

+/-.25

 

0.50

 

0.40

TRIMLINES and CONTOUR SURFACES All trimlines and surfaces must not exceed a rate of

MAXIMUM THICKNESS: 50% OF WALLSTOCK

0.20

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

DOGHOUSE BOTTOM SURFACES

+/-.20

Not to exceed a rate of change of .20mm over a distance of 50mm.

0.20

PROCEDURES MANUAL QUALITY (Section 4) 4.2

General Tooling Tolerances & Specifications

WALLSTOCK

+/-.20



0.40

RADII

+/-.25



0.50

ANGULARITY

+/- 1°

⊃

0.10°

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

SIGNAL LIGHTING

FORWARD LIGHTING

OPTICAL TOOL SURFACE TOLERANCE DIMENSIONS ANGLES EDGE RADII

+/- .10 mm +/- .20 mm 0.26 mm

DIMENSIONS ANGLES EDGE RADII

+/- .05 mm +/- .2 mm 0.125 mm

PROCEDURES MANUAL QUALITY (Section 4) 4.2

Tooling Tolerances & Specifications

GENERAL PLASTIC PART TOLERANCE TABLE

LINEAR DIMENSION

0-3 3-15 15-30 30-70 70-120 120-160 160-200 200-250 250-315 315-400 400-500 500-630 630-800 800-1000

TOLERANCE FOR THE LISTED MATERIAL

EP, PF , PD AP, PESU, U P-BMC, PSU, PET P, ASA, ABS, PMMA, PPO , PA, PBT P, PPS, PS, PC , PVC -P, SAN, SB, PVC-U +/-0.10 +/-0.16 +/-0.20 +/-0.30 +/-0.40 +/-0.48 +/-0.58 +/-0.70 +/-0.86 +/-1.06 +/-1.30 +/-1.60 +/-2.00 +/-2.50

TOLERANCE FOR THE LISTED MATERIAL

+/-0.18 +/-0.26 +/-0.34 +/-0.56 +/-0.82 +/-1.00 +/-1.30 +/-1.60 +/-2.00 +/-2.40 +/-3.00 +/-3.70 +/-4.70 +/-5.80

+/-0.42 +/-0.54 +/-0.68 +/-1.00 +/-1.40 +/-1.70 +/-2.10 +/-2.50 +/-3.10 +/-3.80 +/-4.60 +/-5.80 +/-7.20 +/-9.00

EVA, UF,PETP, PB POM, VP, PP, PP/EPOM, C AB, CAP, SB, PAG, PA66, P A610, PA11, M F, C A, PA12, PE1

TOLERANCE FOR THE LISTED MATERIAL

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

PROCEDURES MANUAL QUALITY (Section 4) 4.3

Control of Machine Controllers & Test Equipment

PURPOSE This procedure pr ovides specific instructions f or t he v erifications, ca librations and t he 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 m aintenance department has the ov erall r esponsibility t o ensu re t his procedure i s being followed. PROCEDURE 

The quality depar tment w ill m aintain t he ca libration r ecords of m achine controllers & t est equipment.



The maintenance depa rtment i s responsible for i dentifying and ca librating a ll m achine 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 f ollowed as outlined in the software program supplied with the ball bar. C NC Milling and B oring m achines will be t ested w ith a ci rcular m ethod and E DM m achine w ill 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. Quality

Officer

Established 10/01/06

Revision 01/19/08

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

Rev # 002

PROCEDURES MANUAL QUALITY (Section 4) 4.3 

Control of Machine Controllers & Test Equipment Calibration will be t agged i ndicating t he n ext due d ate. Depending on how far out of t olerance 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 an y of t hese items ar e f ound o ut of c alibration they will b e r emoved f rom t he s ystem, 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 O ut O f C alibration C hecklist F orm 4. 1 i s t hen r eviewed with t he director of en gineering / manufacturing.



The director of engineering / manufacturing will determine if there is a probability of suspect material / items in process or shipped.



If yes, t he customer w ill be no tified a nd c onsulted with a ny c orrective actions t hat m ay n eed to be taken.

RELATED DOCUMENTATION [appendix] 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

PROCEDURES MANUAL SHIPPING AND RECEIVING (Section 5) 5.1

Shipping & Receiving Customer Molds/Tools/Components

PURPOSE To est ablish a pr ocedure for sp ecifying and m onitoring p roper t ransportation act ivities and shipping pr actices to pr otect the quality of del iverable g oods and t o pr event t heir dam age 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 i s the r esponsibility o f the m old l eader, pr ogram m anager, and t he shipping & r eceiving 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 m olds shipped f rom a P roper T ooling facility ar e sh ipped FO B t he P roper G roup International facility.



All transportation costs are borne by the customer.



All outgoing molds/tools/components will be packe d in accordance with prescribed methods and customer requirements, using materials designed to ensure that the product quality is maintained during t ransit. O rder and product i dentification w ill be cl early m arked and w ill 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.

Issuing Dept. Shipping & Receiving

Officer

Established 09/05/00

Revision 03/13/09

Rev # 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

PROCEDURES MANUAL SHIPPING AND RECEIVING (Section 5) 5.1 

Shipping & Receiving Customer Molds/Tools/Components (continued) Any i ncoming m olds/tools/components scheduled by a t hird par ty and r eceived b y P roper Group International must be verified that damages will not be attributed to the handling of Proper Group International. A ny noticeable damage upon r eceipt must be docu mented on the transporter’s shipping documents.

Mold Shipment For Tryout 

All molds and tools that are completed and bei ng 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 m old has been completed for shipment to the customer’s facility for a pl ant tryout, the following forms must be co mpleted by t he pr ogram manager and su bmitted to the shipping & receiving department.  Request For Shipment Form 5.1  Mold Inspection For Shipment Form 12.6



Once the sh ipping & r eceiving asso ciate r eceives all docu mentation as l isted abov e, t hey 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 p rogram m anager must ob tain a si gned C ustomer A cceptance Fo rm 12 .7 from the proper customer representative.  The program manager will fill out and d istribute the Request For Shipment Form 5.1 using the Customer Acceptance approval date as the Final Shipment date.

PROCEDURES MANUAL SHIPPING AND RECEIVING (Section 5)  5.1

It will be noted in the Additional Instructions section of the form, the actual date that the mold was shipped to the customer. 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 co mpleted by t he pr ogram manager and su bmitted t o t he sh ipping & receiving department.  Request For Shipment Form 5.1  Mold Inspection For Shipment Form 12.6  Customer Acceptance Form 12.7



Once the sh ipping & r eceiving asso ciate r eceives all docu mentation as l isted abov e, t hey 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 sh ipment ca nnot be made due to ou tstanding pu rchase o rders, the shipping & receiving asso ciate will not ify a g eneral m anager 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 t o the cu stomer’s facility, the following forms must be completed by the program manager and su bmitted to the shipping & receiving department.  Request For Shipment Form 5.1.5  First Article Certification Package (if required – reference Section 6.9)



Once the sh ipping & r eceiving asso ciate r eceives all docu mentation as l isted abov e, t hey 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 & r eceiving asso ciate w ill not ify a g eneral m anager or m anufacturing supervisor / manager for authorization to override.

PROCEDURES MANUAL SHIPPING AND RECEIVING (Section 5) 

5.1

if aut horization i s given, t he shipping & receiving a ssociate w ill pr epare t he mold for shipment.

Shipping & Receiving Customer Molds/Tools/Components

Receiving Customer Supplied Product 

Customer supplied product is very limited in the operation of Proper Group International.



Typical cu stomer supplied pr oduct enco mpasses plastic resin, pac kaging, gages, E OA tooling, secondary equipment and mating components.



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

The program

Customer Tools 

All incoming molds received at a P roper Group International facility must be i nspected 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. 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.

The program

100

PROCEDURES MANUAL 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.

101

PROCEDURES MANUAL SHIPPING AND RECEIVING (Section 5) 5.1

Shipping & Receiving Customer Molds/Tools/Components

RELATED DOCUMENTATION [appendix] 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/ I n P rocess Components & M aterial Inspection & N on C onformity 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

102

PROCEDURES MANUAL 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 r eceiving department. The m anaging asso ciate / asso ciate su pervisor 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 m aterial i s ch ecked by t he sh ipping and r eceiving asso ciate i n t erms of co mpliance t o 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

Issuing Dept. Shipping & Receiving

Officer

Established 09/05/00

Rev: Added guidelines for shelf life items.

Revision 03/13/09

Rev # 003

103

PROCEDURES MANUAL SHIPPING AND RECEIVING (Section 5) 5.2

Handling & Storage



Material awaiting use or shipment will be identified and segregated in secure storage areas. Suitable m easures are t aken t o pr event dam age or det erioration i ncluding a per iodic inspection for materials condition.



The shipping and r eceiving depar tment i s responsible t o co nduct r egular audi ting o f t he storage of goods to determine that products are maintained in a sa tisfactory 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 v endor and added t o t he M SDS l isting m aintained on t he P roper Group International network and at m ultiple l ocations within t he m anufacturing ar ea a t t he T oolboss machine data screens.



A l abel w ith t he pr oduct nam e and r eceived dat e ( added by sh ipping & r eceiving) w ill be attached t o the co py of t he pur chase or der by pur chasing and forwarded t o sh ipping & 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 depar tment su pervisors will m onitor t he sh elf l ife for any e ffected items within t heir department.



Every 3 m onths 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 i tems past t heir r ecommended sh elf life / ex piration dat e will be di (appropriately).



The department supervisor will sign the sheet to record that the audit has been completed and any expired i tems have been pr operly d isposed of w ithin t heir ar ea. T his sheet i s returned to the purchasing department where the records are maintained.



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

scarded

104

PROCEDURES MANUAL SHIPPING AND RECEIVING (Section 5) 

5.2

The anal ysis will be p repared on a q uarterly basis for review dur ing t he Quarterly Management M eetings. ( Reference P rocedure – Proper G roup International M eetings Section 2.1). Handling & Storage

RELATED DOCUMENTATION [appendix] 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

105

PROCEDURES MANUAL 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 i s utilized t hroughout al l t he m anufacturing depar tments on co mponents controlled by a First Article Inspection Process (Section 6.9). RESPONSIBILITY It will be t he responsibility of all associates to visually and phy sically verify each component as required by the Work Order Router Form 3.8.5. T he verification should be docu mented on t he 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 as sociate must have t he Work Order R outer Fo rm 3. 8.5. The router w ill pr ovide direction for the process and the need for in-process verification.



Changes in processes are not allowed and m ust be co mpleted 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 i nstruction, quality, m anagement, and manufacturing en gineer m ust be n otified. Product controlled by FAI will require recertification if changes are made.



Upon co mpletion o f a p rocess that r equired v erification, t he as sociate must docu ment the results on the verification on t he Work Order Router Form 3.8.5, also signing and dat ing 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 t agged w ith a r ed N on C onforming Tag an d pl aced i n t he N on C onforming ar ea. The number of items passing and f ailing will be i dentified on t he 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. Manufacturing

Officer

Established 01/19/09

Revision 07/15/09

Rev # 001

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

106

PROCEDURES MANUAL 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 C onforming area to determine if a r ework 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 [appendix] Form – Work Order Router 3.8.5 Procedure – Incoming / I n P rocess Components & M aterial I nspection & N on C onformity 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

107

PROCEDURES MANUAL MANUFACTURING (Section 6) 6.2 Incoming / I n Process C omponents & M aterial I nspection & N on C onformity 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 al l i ncoming m anufactured components, i ncoming pur chased components, and i ncoming r aw st eel m aterial. T his process describes how t o deal with incoming inspections and also nonconformities for the incoming and in process product. RESPONSIBILITY The responsibility of reporting and i dentifying a nonco nformance i s given t o al l asso ciates. Associate su pervisors have t he aut hority t o a ct on a nonco nformance appr opriate 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 o peration, the oper ation will sh ut do wn and t he i tem w ill be yellow tagged immediately.



The m anufacturing 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 w ill be docu mented be docu mented o n t he m anufactured co mponent or through a Change Order Form 3.15 / 3.15.5.  A yellow Not Inspected Tag will be at tached 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 t he co mponent ca n b e m odified w ithout co mpromising cu stomer sp ecifications, 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. Manufacturing

Officer

Established 09/05/00

Revision 07/07/09

Rev: Formatting issues on page 5

Rev # 006

108

PROCEDURES MANUAL MANUFACTURING (Section 6) 6.2 Incoming / I n P rocess C omponents & M aterial I nspection & N on C onformity Guidelines

Manufacturing Components (Controlled by First Article Inspection – Section 6.9) 



The manufacturing asso ciate w ill not ify t he managing asso ciate / asso ciate su pervisor 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 w ill be docu mented on t he Work Order R outer For m 3. 8.5 de tailing t he processes to be added or reran.  The y ellow t ag w ill be r emoved by a q uality representative af ter the r ework i s completed.  Rework can be r erunning of the same operation or adding an oper ation providing it does not affect the part specifications or quality.



Replace (non-repairable)  A non -repairable co mponent w ill be t agged w ith a r ed N on C onforming Tag. The tags must be filled out and the item will be sent to the nonconforming area.

Incoming Components 

Incoming components used i n t he m anufacturing p rocess ar e ei ther 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.

109

PROCEDURES MANUAL MANUFACTURING (Section 6) 6.2 Incoming / I n P rocess C omponents & M aterial I nspection & N on C onformity Guidelines 

Upon completion of this inspection a green OK To Process Tag will b e 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 non conformity i s found, the decision w ill be m ade w ith 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 r ed Non Conforming Tag attached, filled out, and sent to the nonconforming area (Aerospace Only).

Purchased Components 

All in coming purchased co mponents will be i nspected for t he co rrect ca talog nu mber, amount, and any special instructions at the time of the order.



Purchased co mponents w ill not be i nspected for di mensional sp ecifications. 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 not ified of the incorrect product and the product will be returned for the correct item.

These

110

PROCEDURES MANUAL MANUFACTURING (Section 6) Incoming Raw Steel Cavity & Core Die Block 

All incoming raw st eel 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 bl ocks that a re p urchased by t he cu stomer do not r equire st eel ce rtification. The customer will receive these at their facility when the steel is purchased.

6.2 Incoming / I n P rocess C omponents & M aterial I nspection & N on C onformity 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 s tandard stock, the material will be i dentified for the detail and job numbers.



All sh ort pi eces removed o ff of the or iginal bar st ock must be i dentified by co lor or st eel nomenclature.

Incoming Raw Materials – FAI Controlled Components 

All i ncoming raw m aterials will be v erified per the Work Order R outer Form 3. 8.5. The certifications if required will be r eviewed to insure they meet the specifications or standards listed on the router.



The review w ill v erify t hat t he el ements of t he ce rtification match t he sp ecification o r 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.

111

PROCEDURES MANUAL MANUFACTURING (Section 6) 

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 / I n P rocess C omponents & M aterial I nspection & N on C onformity 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 co mponents in the N on C onforming ar ea m ust be red tagged and e ntered i n the N on Conforming Product Log Form 6.2.



The manufacturing supervisor and t he quality manager will review on a d aily 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 onl y be r elabeled as OK to P rocess b y a q uality representative after the reworked components pass verification or inspection.



If the pr oducts are to b e scr apped, t he red N on C onforming Tag w ill b e not ed “ Scrap Part.”  Products to be sc rapped will be r eviewed on a weekly basi s with t he g eneral manager and t hen w ill be scr apped by sa wing the pi ece i n hal f or dest roying i n a method that rends them unusable.



A deviation is to be requested from the customer to vary the product specification.

112

PROCEDURES MANUAL MANUFACTURING (Section 6)    

The vice pr esident o f P roper Aerospace and the quality manager will be notified. They w ill deci de i f a pr oduct dev iation will be r equested for t he cu stomer or i f t he other two options are to be chosen. All product deviations will be documented in written form denoting the specification change. The pa rts will ha ve t he r ed N on C onforming T ag r emoved w hen t he dev iation approval is obtained in writing. The parts will then be identified per customer’s specifications for deviated parts.

6.2 Incoming / I n P rocess C omponents & M aterial I nspection & N on C onformity Guidelines RELATED DOCUMENTATION [appendix] 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

113

PROCEDURES MANUAL MANUFACTURING (Section 6) 6.3

Product Identification

PURPOSE To identify all m anufactured and purchased components that a re used to produce complete mold assemblies. SCOPE To ensure all products and/or components are clearly identified for proper use. RESPONSIBILITY All associates involved throughout the manufacturing process are responsible. PROCEDURE Manufactured Components (prototype & production) 

All details that are custom manufactured for a specific mold will have the following identification: 

Tooling C omponents will be i dentified by st amping, en graving, or m achining i nto t he work piece in a permanent non-removable location. Identification will include:  Project Number  Material Used  Detail Number (if applicable)



Manufactured co mponents controlled by a Fi rst A rticle I nspection ( Section 6. 9) w ill be identified per the instructions on the Work Order Router Form 3.8.5.



All mold bases used for production molds are to be identified with the project number.



Identification will be as follows: 

Cavity and core blocks will have the project number machined onto the parting line.



Ejector plates, rails, and clamp pates will have the project number stamped on the plate thickness side at final assembly.

NOTE: Identification of the plates throughout the manufacturing phase will be by ink marking, labels or stamping.

Issuing Dept. Manufacturing

Officer

Established 09/05/00

Rev: Modified for tooling and manufactured components

Revision 01/19/09

Rev # 003

114

PROCEDURES MANUAL MANUFACTURING (Section 6) 6.3

Product Identification (continued)

Purchased Components 

All components received for a specific project will be identified at receiving with ink marking on the packaging that the product is received.



If products are removed from the packaging the following applies: Small Components  All small components i.e. screws, dowels, electrics, etc. will be placed in bins with the bins clearly identified. Large Components  Larger co mponents such as hydraulic cylinders will be identified by tagging o f i nk marking.

RELATED DOCUMENTATION [appendix] Form – Work Order Router 3.8.5 Procedure – First Article Inspection Section 6.9 Level 1 – Identification and Traceability Section 7.5.3

115

PROCEDURES MANUAL MANUFACTURING (Section 6) 6.4

Contingency Plan For In Process Work

PURPOSE To hav e a co rporate w ide pl an t o ensu re t he cu stomers product i s not di srupted due to equipment, facilities, or natural disasters. SCOPE Applies to all Proper Group International facilities. RESPONSIBILITY It i s the r esponsibility of t he management t eam of t he P roper Group I nternational t o react as needed during a crisis event. PROCEDURE

Equipment Failures

In the event of key equipment failure, the following procedure is followed: 

Rescheduling the project through different equipment or operations if possible.



Review Proper Group International facilities to take over the project.



Contact and ut ilize Proper Group International’s vast subcontractor base for the completion of the project.

Utility Interruptions

In the event of power outage, the management team will: 

Evaluate the length of the outage.



Evaluate all in work process for impact of power outage.



Develop a new schedule modifying current manufacturing process plan.



If molds need to be removed outside of the facility to continue manufacturing during a power outage, the management team will utilize dedicated rigging companies to lift and transport molds. Issuing Dept. Manufacturing

Officer

Established 09/05/00

Revision 01/19/09

Rev: Updated with new name and logo.

Rev # 002

116

PROCEDURES MANUAL MANUFACTURING (Section 6)

6.4

Contingency Plan For In Process Work (continued)

Labor Shortages 

Proper Group International’s vast subcontractor base may be u sed to compensate for labor shortages due to vacations and capacity issues.

Natural Disasters 

Natural disasters are handled between the management team and t he corporate insurance underwriters.



Our p rocedures listed a bove will be ut ilized t hroughout al l t he phase s of nat ural di saster depending on the impact to a Proper Group International facility.

RELATED DOCUMENTATION [appendix] Level 1 – Infrastructure Section 6.3 Level 1 – Planning of Product Realization Section 7.1

117

PROCEDURES MANUAL MANUFACTURING (Section 6) 6.5.5 Aerospace Servicing PURPOSE This procedure provides specific instructions for communication of service, maintenance, and warranty related items to components serviced by Proper Aerospace. SCOPE This applies to all work performed on manufactured by Proper Aerospace which occurs in house and at the customer’s facility. RESPONSIBILITY The managing associate / associate supervisor of manufacturing has the overall responsibility to ensure these procedures are being followed. PROCEDURE Customer On Site Service  If a manufacturing engineer, quality or manufacturing associate is sent out to service a component at a customer’s facility, a Service Report Form 6.5.5 is filled out.  Upon co mpletion, t he P roper A erospace asso ciate and cu stomer si gns t he S ervice R eport Form 6.5.5.  The form is forwarded to the managing associate / associate supervisor of manufacturing.  The managing associate / associate supervisor of manufacturing reviews the report and adds any applicable comments or additional information and distributes the report as follows:  Quality Department – for analysis of any cost implications and a Change Order Form 3.15.5 is written on all service calls.  Manufacturing Engineer – for review. The manufacturing engineer is responsible to do a thorough review to monitor the reasons for the services from a manufacturing aspect. After reviewing, t he m anufacturing en gineer m ust i nitial t he f orm and f orward t o adm inistrative associate for filing in the master job file.  In t he ev ent t hat se rvicing i s due to P roper A erospace’s manufacturing, t he manufacturing engineer w ill r eview t he m anufacturing docu mentation w ith q uality and m anufacturing and make corrections as necessary.

Issuing Dept. Manufacturing

Officer

Established 02/01/09

Revision

Rev: New procedure & forms.

Rev #

Release

118

PROCEDURES MANUAL MANUFACTURING (Section 6) 6.5.5 Aerospace Servicing (continued) 

If a component is at Proper Aerospace and needs service work, a Change Order Form 3.15.5 is filled out.



The Change Orders Procedure 3.15.5 is then followed.

RELATED DOCUMENTATION [appendix] Form – Change Order 3.15.5 Form – Service Report 6.5.5 Procedure – Change Orders Section 3.15.5 Procedure – Associate Travel & Expenditure Procedures Section 6.6 Procedure – Service Group Associate Guideline Section 6.7 Level 1 – Validation of Processes for Production and Service Provision Section 7.5.2

119

PROCEDURES MANUAL MANUFACTURING (Section 6) 6.5

Servicing

PURPOSE This procedure p rovides specific instructions for co mmunication o f se rvice, m aintenance, and warranty related items on tools serviced by Proper Tooling. SCOPE This applies to all work performed on tools serviced by Proper Tooling which occurs in house and at the customer’s facility. RESPONSIBILITY The g eneral manager has the overall responsibility to ensure these procedures are being followed. PROCEDURE Customer On Site Service 

If a m old technician is sent out to service on a m old at a customer’s facility, a Mold Service Report Form 6.5 is filled out.



Upon completion, the mold technician and the customer signs the Mold Service Report Form 6.5.



The form is forwarded to the general manager.



The general manager is responsible to do a thorough review to monitor the reasons for the services from a manufacturing aspect.



After r eviewing, the general m anager m ust add appl icable co mments or addi tional information, initial the form and forward one copy to the administrative associate of program management to file in the master job file and one copy to the program manager.



The program manager will analyze the Mold Service Report Form 6.5 and determine if there are any co st i mplications or ch anges in s cope. I f this is the case, a C hange Order Fo rm 3.15 is completed to document the changes.



In the event that mold servicing is due to the Proper Tooling’s design or manufacturing of the m old, t he general m anager will assemble t he appr opriate t eam to r eview t he desi gns and/or manufacturing documentation and make corrections as necessary. Issuing Dept. Manufacturing

Officer

Established 01/01/01

Revision 03/13/09

Rev # 006

Rev: Form 6.5 is filed in master job file, prg mgr analyzes form for changes or further work.

120

PROCEDURES MANUAL MANUFACTURING (Section 6) 6.5

Servicing (continued)

Proper Tooling Facility Service 

If a m old i s at P roper Tooling and needs service work, a C hange Order For m 3 .15 is completed by the program manger.



The C hange O rders P rocedure 3. 15 o f P roper Group International’s Manual i s then followed.

RELATED DOCUMENTATION Form – Change Order 3.15 Form – Mold Service Report 6.5 Procedure – Change Orders Section 3.15 Procedure – Mold Service Group Procedures Section 6.6 Procedure – Mold Service Group Associate Guideline Section 6.7 Level 1 – Validation of Processes for Production and Service Provision

121

PROCEDURES MANUAL MANUFACTURING (Section 6) 6.6 Associate Travel & Expenditure Procedures PURPOSE This procedure pr ovides specific instructions for m anaging a nd r eimbursing asso ciates for performing service work or other work outside Proper Group International facilities. SCOPE This applies to al l w ork performed on tools serviced b y P roper T ooling, w hich occu rs at the customer’s facility and also al l work / du ties performed ou tside o f the P roper Group Internal facilities. RESPONSIBILITY The co ordinator for out side se rvice w ork and / or the travel co ordinator has t he ov erall responsibility to ensure these procedures are being followed PROCEDURE TRAVEL ARRANGEMENTS 

When an associate needs to make travel reservations for company business, the Request For Travel Form 6.6 must be filled out completely. T he signature of a m anaging associate must be included on the form before any arrangements can be made.



The completed Request For Travel Arrangements Form 6.6 must be submitted to the travel coordinator as promptly as possible. Once the reservations are confirmed, the associate will receive a complete travel package.



If a cash advance is required for the business trip, the associate must fill out the Cash Advance Request Form 6.6a and submit it to the travel coordinator. I ncluded in the travel package will be an E xpense Report Form 6.6b with the cash advance noted. The Expense Report Form 6.6b must be turned in at completion of travel. CASH ADVANCE



All Cash Advance Request Form 6.6a need to be submitted in advance as far in advance as possible since reimbursements are made only on Fridays. Cash advances may be obtained in the form of cash or a check.



An officer of the company must approve all Cash Advance Requests Form 6.6a.

Issuing Dept. Manufacturing

Officer

Established 02/18/02

Revision 01/19/09

Rev: Updated with current information, and changed procedure name.

Rev # 003

122

PROCEDURES MANUAL MANUFACTURING (Section 6) 6.6 Associate Travel & Expenditure Procedures (continued) 

Some examples of items that may require a cash advance include computer supplies, travel advances, or C.O.D. items.



All cash advance money must be reported on an Expense Report Form 6.6b with attached receipts.



It i s the r esponsibility of t he asso ciate r equesting t he ca sh adv ance t o r eturn any unuse d portion of the money along with the expense report on a t imely basis. If the unused portion of t he ca sh adv ance i s not r eturned, t he money will be deduct ed f rom t he as sociate’s paycheck. Recurring incidents will result in revocation of cash advance privileges.



If the cash advance is for t ravel pay, it m ust be turned in w ith t he Travel / Work Hours Report Form 6.6c



At no time will Cash Advances be used for entertainment. TRAVEL EXPENSE POLICY



Alternate W ork Locat ion – the al ternate w ork location i s the pl ace t hat t he asso ciate i s requested to travel, to complete a special task or job responsibility in order to meet business needs.

Domestic Travel Guidelines 

Airfare – a coach class ticket will be pr ovided to the associate when he/she must fly to the alternate work location. I n general, the least cost and m ost direct route will be chosen. Air travel is a requested option when driving distance exceeds six hours one way.



Vehicle – when necessary, an intermediate-sized vehicle with unlimited mileage is provided. The company will pay for driving privileges for the associate only.



Hotel – when o vernight travel is required, the company will pa y for hotel accommodations that a re cl assified a s standard t o i ntermediate. T he pr ice o f acco mmodations should be reasonable for the area and in general, should not exceed $120.00 per night plus taxes and surcharges (ie Hampton Inn, Holiday Inn Express).



Other hotel expenses listed below will be t he responsibility of the associate and w ill not be paid for by the company.  Movies / Entertainment  Sundries  Phone Calls

123

PROCEDURES MANUAL MANUFACTURING (Section 6) 6.6 Associate Travel & Expenditure Procedures (continued) 

Meals – The company does not grant a pe r-diem; however, the company will pay for meal expenses in accordance with the guidelines below when the associate must stay overnight (away from home) due t o a work-related assignment. T he company will pay for breakfast, lunch, and/or dinner when the term of the assignment is during these times. T he company will r eimburse t he asso ciate for t he actual cost of t he pr incipal m eal up t o the am ounts listed below: Breakfast Lunch Dinner

$10.00 $15.00 $30.00



Expenses that exceed the parameters listed above will not be pai d for by the company and are t he r esponsibility of t he asso ciate. T he ac tual r eceipts must be at tached i n or der t o receive reimbursement for breakfast, lunch, or dinner.



In the case when travel is not overnight, but would cause the associate to miss a principal meal (breakfast, lunch, or dinner) during times of travel only, the company will reimburse the associate for the actual cost of his/her principal meal up to the amounts listed above.

International Travel Guidelines 

The international procedures for ai rfare, vehicle, and hotel are the same as those procedures established for Domestic Travel Guidelines, subject to adjustment base on the international destination.



Meals – the guidelines for domestic meals are the same for international meals; however, the co mpany w ill r eimburse t he asso ciate for the act ual co st o f t he pr incipal m eal up t he amounts listed below: Breakfast Lunch Dinner

$20.00 $30.00 $45.00

International Exchange Rates 

The ass ociate w ill be r equired to use ac tual or the av erage r ate as published i n t he Wall Street Journal. In general, the associate should charge expenses on a credit card to receive current exchange rate without incurring exchange premiums.

124

PROCEDURES MANUAL MANUFACTURING (Section 6) Record Keeping Requirements 

All expenses relating to business travel both domestic and international must be su bmitted according to the guidelines listed in the Expense Report section of this procedure.

6.6 Associate Travel & Expenditure Procedures TRAVEL PAY POLICY    

Principal Work Location – the principal work location is the facility in which the associate normally reports to work to complete his/her principal job duties. Alternate W ork Locat ion – the al ternate w ork location i s the pl ace t hat t he asso ciate i s requested to travel, to complete a special task or job responsibility in order to meet business needs. Public T ransportation – public transportation i s defined as transportation v ia ai rplane or train. Meal Period / Meal Periods – the time that the associate spends for lunch or dinner.

Travel Pay Rates 

Consistent with state and federal wage and hour guidelines, travel pay is compensated at the regular, overtime, and double time rates as listed in the Associate Handbook.

Travel from Home to Principal Work Location 

The company does not pay for the time that an associate spends traveling to his/her principal w ork l ocation from ho me except in sp ecial ci rcumstances. This is considered normal commuting time.

Travel from Home to Alternate Work Location 

When leaving from home to an alternate work location, the company will pay for the amount of miles over the normal commute to the principle work location.  Example: If an asso ciate leaves from home and drives to X YZ Company, and i t takes him 45 m inutes and hi s normal co mmuting time t o w ork i s 30 minutes, t hen t he associate will be paid for 15 minutes of travel time.

125

PROCEDURES MANUAL MANUFACTURING (Section 6)

Travel from Hotel to Alternate Work Location 

Proper Group International does not pay for the time an associate spends traveling to and from the ho tel t o t he al ternate w ork l ocation w hen ov ernight t ravel i s required. This is considered as normal commuting time.

Travel from Home to Principal or Alternate Work Location to Home in Special Circumstances 

As stated above, travel to and from the principal work location is not considered travel time except when an asso ciate has already co mpleted hi s/her w orkday a nd beca use o f a business need, is required to come back to the principal work location or go to an alternate work location. In this case, the associate will be paid for the time worked and the travel time to and from the principal or alternate work location.

6.6 Associate Travel & Expenditure Procedures 

Example: I f a fter completing hi s/her w ork day, an asso ciate l eaves from ho me an d travels 30 minutes to his/her principal work location to pick up t ools, travels 30 minutes to X YZ C ompany, w orks for 3 hour s, and t ravels 1 hour t o g et bac k h ome, t hen t he associate will be paid for 5 hours.

Roundtrip Travel from Principal Work Location to Alternate Work Location(s) to Principle Work Location

When driving by vehicle  The company will pay for the time spent traveling by vehicle to an alternate work location and back to the associate’s principal work location.  Example: I f an asso ciate l eaves from hi s/her pr incipal work l ocation and dr ives 30 minutes to XYZ C ompany, w orks 9 hour s, a nd dr ives 30 minutes back to hi s/her principal work location, then the associate will be paid 10 hours less any meal period.

When Traveling via Public Transportation

The co mpany w ill pay f or al l of the di rect time sp ent t raveling t o g et to t he al ternate w ork location as well as returning back subject to the guidelines listed below:  Travel and Waiting Time – Proper Group International will pay up to three (3) hours before an international flight or two (2) hours before a domestic flight. (NOTE: This is based on current airline recommendations, rules & regulations). This will be in addition to the

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PROCEDURES MANUAL MANUFACTURING (Section 6)



associate’s commute to the airport over his/her normal commute from home to their principal work location. Time Spent Traveling back to the Principle Work Location – Proper Group International will pay up t o 1 ½ hour s a fter t he flight l ands to return bac k to the asso ciate’s principle w ork location.  Example: On Tuesday, the flight departs from Detroit-Metro airport at 7:00 a.m. to arrive at Greenville airport at 8:30 a.m., associate picks up the rental car and arrives at Proper Polymers – Anderson at 10:00 a.m., works until 7:00 p.m. and then goes to the hotel. The associate will be paid from 6:00 a.m. until 7:00 p.m. less any meal periods. On Wednesday, the associate leaves from the hotel and arrives at Proper Polymers Anderson at 7:00 a.m., works until 5:00 p.m., drives to the airport and returns the rental car and has a departing flight at 7:00 p.m. The associate returns to Detroit-Metro airport at 8:30 p.m. In this case, the associate will be paid from 7:00 a.m. until 10:00 p.m. less any meal period.

Record Keeping Requirements 

When an associate travels out of the area, the associate must fill a Travel Work Hours Report For m 6. 6c as listed i n t he Tr avel / Work H ours Report guidelines listed i n t his procedure. Upon approval, this form is submitted to payroll for processing.

6.6 Associate Travel & Expenditure Procedures

General Guidelines 

The maximum time that an associate may work and travel in one day is 16 hours. In the event that the associate will exceed 16 hours of work and travel in one day, then he/she will be required to stay overnight and travel back to the principle work location the following day. The associate must notify his/her supervisor immediately of any changes in the travel schedule.



Proper Group International will pay time using the most efficient mode of transportation. The co mpany will ca lculate t ravel t ime pay usi ng app roximations from pr evious travel situations if an associate decides to use a mode that takes longer than the one recommended.



Proper Group International w ill deduct nor mal m eal per iod dur ing t he workday w hen su ch time is taken.

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PROCEDURES MANUAL MANUFACTURING (Section 6)



Proper Group I nternational w ill not pay f or the time sp ent w aiting for a st and-by f light o r waiting to make alternate arrangements due to an associate’s poor planning. It is expected that any associate traveling on company business will allow the appropriate amount of time to arrive at the airport.



These forms will be pr ovided t o t he asso ciate by t he t ravel co ordinator al ong w ith t ravel documents. The associate should consult with the travel coordinator or supervisor if they have any questions. TRAVEL / WORK HOURS REPORT

     

Work Week – the days worked between Monday and Sunday. Travel Hours – The time that an a ssociate spends traveling to and from the alternate work location from his/her principal work location. Work Hours – The time that the associate spends performing his/her principle job duties. Meal Periods – The time that the associate spends for lunch or dinner. Principal Work Location – The principal work location is the facility in which the associate normally reports to work to complete his/her principal job duties. Alternate W ork Locat ion – The al ternate w ork location i s the pl ace t hat t he asso ciate i s requested to travel, to complete a special task or job responsibility in order to meet business needs.

Travel / Work Hours Report Guidelines 

When any associate is gone from the office on business, he/she must complete a Travel / Work Hours Report Form 6.6c, which must be turned into the payroll department.



All Travel / Work Hours Report Form 6.6c must be completed in ink. No pencil copies will be accepted.

6.6 Associate Travel & Expenditure Procedures 

A Travel / Work Hours Report Form 6.6c will n ot be acce pted unless it is accompanied by the pr oper app roval si gnatures. S hould y ou h ave t o t ravel t o an alternate w ork location, making you unable to log in and out of the electronic time clock system, you will be required to complete this form and have it signed by your supervisor in order to be paid. The form is then forwarded to the payroll department for processing.

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PROCEDURES MANUAL MANUFACTURING (Section 6)

Travel / Work Hours Report – Form Completion Procedures 

All information pertaining to your travel and work hours for the day or work week should be included on the form. Be sure to include your name, the date(s) you traveled, the travel time to and from the al ternate w ork l ocation from y our pr incipal w ork l ocation or t he ho tel, t he actual time spent working, and any lunch or dinner breaks if applicable. If an area of the form does not appl y t o your ci rcumstance, pl ease i ndicate t his by writing “n/a” in the box. Once completed, you must have your supervisor approve your travel and work hours prior to submitting it to the payroll department.



The travel co ordinator will pr ovide this form to the asso ciate al ong with ot her t ravel documents. Consult with the travel coordinator or your supervisor if you have any questions. MILEAGE LOG FOR PERSONAL VEHICLES

Mileage Log for Personal Vehicles – General 

Mileage l ogs are a means by w hich P roper G roup I nternational ca n r eimburse t he associates for use of their personal vehicle for company business.



The reimbursement is intended to cover all aspects of driving including gas, insurance, wear and tear, general maintenance, etc.



Work Week – Starting on Monday through until the following Sunday.

Mileage Log Guidelines - General 

All Mileage Log For Personal Vehicles Form 6.6d must be completed in ink. No pencil copies will be accepted.



If you use your personal vehicle for company business, you must complete and su bmit this form within one month from the date of use. Delays in submitting Mileage Logs after one month could result in delayed or rejected reimbursement.



No Mileage Log For Personal Vehicles Form 6.6d will be acce pted unless it has the proper approval signatures.

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PROCEDURES MANUAL MANUFACTURING (Section 6) 6.6 Associate Travel & Expenditure Procedures (continued) 

See the office administrator for the current mileage rate.



Mileage will be reimbursed after the documentation submitted has been reviewed and approved. Mileage Logs submitted prior to the 15th of each month will be paid by the end of the month. Mileage Logs submitted between the 15th and the end of each month will be paid by the 15th of the following month. Reimbursements will not be paid in cash, but will be paid by company check.

Mileage Log – Form Completion Procedures 

All information about your trip should be included on the Mileage Log For Personal Vehicles Form 6.6d.



Include the following:  your name  the date you submitted the request for reimbursement  the date you used your personal vehicle for company business  the company you visited  the job number related to your trip (if applicable)  the number of miles you traveled



Once this information has been entered onto the form, total the amount of miles you traveled and subtract any reimbursed miles (where applicable) to find the mileage to reimburse. This number should then be multiplied by the current mileage rate. This number is the amount that you will be reimbursed.



Once co mpleted, y ou m ust hav e an asso ciate s upervisor or m anaging associate approve your reimbursement form prior to submission for reimbursement. EXPENSE REPORT

Expense Report Overview 

Expense R eports are a m ethod t o o rganize e xpense i nformation for internal r eporting purposes, and to make it easier for associates to be reimbursed. In addition, this procedure will meet the documentation requirements set by the Internal Revenue Service.

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PROCEDURES MANUAL MANUFACTURING (Section 6) 6.6 Associate Travel & Expenditure Procedures (continued) 

Proper Group International grants the management team, program managers, and sales associates the privilege of utilizing this expense system. However, should other associates incur expenses directly related to Proper Group International, reimbursements will be m ade when properly authorized.

Expense Report Guidelines - General 

All E xpense R eports Form 6 .6b must be completed i n i nk. N o pen cil co pies will be accepted.



All Expense Reports Form 6.6b must be filled out in complete detail and accompanied by receipts substantiating all expenses. On the back of each receipt the following criteria must be identified:  Date  Proper Group International’s Associate Name  Customer Company Name (if applicable)  Customer Contact Name (if applicable)  Discussion Purpose or Job Number



If you are using a company credit card or cash advance, your Expense Report Form 6.6b should be su bmitted for reimbursement on a w eekly basis. If you are using your own credit card or cash, you should submit an expense report no more frequently than weekly, and no later than monthly. Delays in submitting expenditures after a month could result in delayed or rejected reimbursement.



All Expense Reports Form 6.6b for sales associates are forwarded to the office manager for distribution.



Expenses will be r eimbursed a fter the docu mentation su bmitted has b een r eviewed and approved. E xpense R eports For m 6 .6b s ubmitted pr ior t o t he 15 th of e ach m onth w ill be paid by the end of the month. E xpense Reports Form 6.6b submitted between the 15th of each month will be paid by the 15th of the following month. Reimbursements will not be paid in cash, but will be paid by company check.

Expenditure Guidelines 

Expense Reports Form 6.6b are used for the sole purpose of covering expenses, which are directly related to the Proper Group International’s business.



Items that use an Expense Report Form 6.6b:

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PROCEDURES MANUAL MANUFACTURING (Section 6) 

Any purchase made with cash that is not reimbursable from the Petty Cash account.



All cr edit ca rd pur chases along w ith t he det ailed r eceipt MUST be t urned i n on an Expense Report Form 6.6b. C redit card purchases may be on an associate’s personal credit card or one issued by the company. Season Ticket Detail Tag



6.6 Associate Travel & Expenditure Procedures 

Examples of the types of items that may appear on an expense report are:  Gas, road tolls, hotel, meals and tips, cabs, transportation, gratuities, misc. travel costs, and entertainment events.  Unreimbursed business mileage on personal vehicles (if mileage log is not used).

Internal Revenue Service Guidelines 

The Internal R evenue S ervice al so has strict guidelines as to w hat m ay and m ay not be accepted as a business expenditure for taxation purposes.



In addition, the I.R.S. Regulations state that a b usiness related discussion must take place prior to the event, during, or immediately after the event being attended.



This guideline must also be followed when event tickets are given to a customer, in which a Proper G roup International associate w ill not be at tending t he ev ent. A busi ness related discussion m ust t ake pl ace pr ior to giving out t he t ickets or i mmediately t hereafter. The minimum criteria to be met is as follows:  Event  Proper Group International’s Associate Name  Customer Company Name  Customer Contact Name  Place of Discussion  Date  Discussion Purpose or Job Number 

NOTE: This information must be recorded on an Expense Report Form 6.6b, so that the associate may be reimbursed for any costs incurred. In addition, this information will be used as documentation for reporting purposes to the I.R.S.



If se ason t ickets are us ed, t his information must be i ncluded on t he S eason T icket D etail Tag and stapled to the Expense Report for the event attended.



In addition, the associate must identify the specific state(s) or countries, and the number of days spent outside the State of Michigan. For example, if you traveled to Ohio in the

132

PROCEDURES MANUAL MANUFACTURING (Section 6) afternoon, stayed the night, and came back the next morning, this should be l isted on y our Expense Report Form 6.6b as two (2) days in Ohio.



This information w ill be accu mulated on an i ndividual basi s by means of the E xpense Reports. I t w ill be ea ch asso ciate’s responsibility to co mplete t he “ OUT OF S TATE TRAVEL” box l ocated i n the bottom left corner of the Expense Report Form 6.6b. This information is not only for overnight travel. The box must also be completed if travel is only for a few hours out of the state during the day (i.e. Windsor).

6.6 Associate Travel & Expenditure Procedures OUTCOME 

The following paperwork will be completed upon the completion of mold services:  Request For Travel Form 6.6  Cash Advance Form 6.6a  Expense Report Form 6.6b  Travel / Work Hours Report 6.6c  Mileage Log for Personal Vehicles 6.6d

RELATED DOCUMENTATION [appendix] Form – Request For Travel 6.6 Form – Cash Advance 6.6a Form – Expense Report 6.6b Form – Travel / Work Hours Report 6.6c Form – Mileage Log for Personal Vehicles 6.6d Procedure – Training & Development Section 1.1 Procedure – Servicing Section 6.5 Procedure – Mold Service Group Associate Guideline Section 6.7 Tag – Season Ticket Detail

133

PROCEDURES MANUAL MANUFACTURING (Section 6) 6.7 Service Group Associate Guideline PURPOSE This procedure pr ovides specific instructions for co mmunicating, docu menting, and sa tisfying customer and associate activities while at the customer’s facility. SCOPE This applies to al l work per formed on t ools or co mponents serviced by International which occurs at the customer’s facility.

Proper G roup

RESPONSIBILITY The associate at the customer’s facility has the overall responsibility to ensure that these procedures are being followed. PROCEDURE Customer On Site Service 

Once t he as sociate has l eft for a cu stomer’s facility, t hey sh ould ha ve a co mplete t ravel package, including Forms 6.6c, 6.6d, 6.6e, and 6.5 or 6.5.5 Service Report.



Once the associate has made contact with the customer, they should get complete and clear direction on what needs to be accomplished in the most efficient manner possible.



The associate will usually be visiting a customer’s facility for one of three items:  New mold start up or warranty claim (non-billable)  Repair or emergency service (billable to the customer)  Mistakes from incorrectly performed work previously done by the associate



Once t he w ork i s performed or r eviewed, t he asso ciate m ust co mmunicate w ith t heir supervisor at the Proper Tooling facility and update everyone as to the problem or circumstance of what work is being performed.



Once the work is performed and complete, the Mold Service Report Form 6.5 or Aerospace Service R eport For m 6 .5.5 m ust be filled out and si gned by bot h t he asso ciate and t he customer.



The associate will be pai d per the specifications on 6.6 and through their completion of the Travel Work Report 6.6c, normal rates and procedures apply. Issuing Dept. Manufacturing

Officer

Established 02/18/02

Revision 01/19/09

Rev: Removed additional pay rates and premium information

Rev # 003

134

PROCEDURES MANUAL MANUFACTURING (Section 6) 6.7 Service Group Associate Guideline (continued) 

Upon r eturn t o P roper G roup I nternational, t he asso ciate m ust r eturn the four co mplete forms outlined below, to their supervisor to be h anded in for payroll payment and expense report accounting.  Mold Service Report Form 6.5 or Aerospace Service Report Form 6.5.5  Expense Report Detail Form 6.6b  Travel / Work Hours Report Form 6.6c  Mileage Log for Personal Vehicle Form 6.6d

RELATED DOCUMENTATION [appendix] Form – Mold Service Report 6.5 Form – Aerospace Service Report 6.5.5 Form – Expense Report Detail 6.6b Form – Travel / Work Hours Report 6.6c Form – Mileage Log for Personal Vehicle 6.6d Procedure – Servicing Section 6.5 Procedure – Associate Travel & Expenditure Procedures Section 6.6

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PROCEDURES MANUAL MANUFACTURING (Section 6) 6.8 Welding PURPOSE This procedure provides specific instructions for welding on tools by the PME Companies. SCOPE This applies to all welding performed on t ools by the PME Companies, which occurs in house and at the customer’s facility. RESPONSIBILITY The managing associate / associate supervisor of manufacturing has the overall responsibility to ensure these procedures are being followed. PROCEDURE Customer On Site Welding 

If a mold / welding technician is sent out to service a mold that requires welding, a digital picture will be taken of the area prior to, and after the welding is complete.



Any areas requiring weld to a C lass ‘A’ surface will require (preferably) a sign off from the customer be fore w elding, or v erbal appr oval f rom a managing asso ciate / a ssociate supervisor at the PME Companies.



The managing associate / associate supervisor’s name that gave the approval will be recorded on the Mold Service Report Form 6.5.



The digital pictures will be processed, and evaluated by the managing associate / associate supervisor, and kept in the quality department with the job file upon return of the technician.

PME Facility Welding 

If a mold / welding technician is required to weld on a tool, it is required to document on an 8 ½ x 11 screen dump the area welded. 

The 8 ½ x 11 docu ment will be r eviewed by the associate supervisor and forwarded to the quality department for the job file.

Issuing Dept. Manufacturing

Officer

Established 03/01/04

Revision 10/01/06

Rev: Revised for new ISO standard.

Rev # 001

136

PROCEDURES MANUAL MANUFACTURING (Section 6) 6.8 Welding (continued) 

Welding on a C lass ‘A’ surface r equires a digital pi cture p rior to and a fter w elding, o f the area requiring weld. 



The digital pictures will be pr ocessed by the managing associate / associate supervisor and kept in the quality department with the job file.

Engineering changes requiring weld with EDM or machining afterwards will require a weld map. 

Copies of the weld maps will be forwarded to the quality room to be kept in the job file.



All m olds that r equire terminally welding will require t he ov en t emperature H oneywell Circular Charts.



Copies of the Honeywell Circular Chart will be forwarded to the quality room, and kept in the job file.



All molds that are terminally welded on t he pre-heater will require a m anual Circular Chart, and forwarded to the quality department.

RELATED DOCUMENTATION [appendix] Form – Mold Service Report 6.5 Level 1 – Control of Production and Service Provision Section 7.5.1 Reference – Honeywell Circular Charts

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PROCEDURES MANUAL MANUFACTURING (Section 6) 6.9

First Article Inspection

PURPOSE This procedure ou tlines the r equirements for per forming and docu menting Fi rst A rticle Inspection (FAI) and First Article Inspection Reporting (FAIR). SCOPE All components requiring First Article Inspection. RESPONSIBILITY It i s t he r esponsibility of t he sales associate or program manager t o i dentify al l pr ograms or revisions that r equire Fi rst A rticle i nspections as identified by t he cu stomers purchase or der. The P roject A PQP P lan For m 3. 3.5 and the Change Order For m 3 .15.5 w ill be use d t o communicate this need throughout the organization. The quality manager will be responsible to ensure the FAI is completed on items that represent the production process. Prototype or parts manufactured usi ng m ethods different from t he normal pr oduction pr ocess can not be use d. The r esults of t he Fi rst A rticle I nspection w ill be r ecorded on forms 6.9, 6. 9a, and 6. 9b a s applicable. PROCEDURE The quality manager will insure full First Article Inspections are completed on al l new products as identified in the Project APQP Plan Form 3.3.5. The FAI requirement shall continue to apply even af ter i nitial co mpliance. I f any par t, pr ocess changes occur or w hen any of t he ev ents listed below take place a full or partial First Article Inspection must be preformed.     

A change in the part design that affects fit, form or the function of the part. A change in the manufacturing source, process, inspection method, location of manufacturing, tooling, or material that could affect fit, form or function. A change in the numerical control program or translation to another media that could affect fit, form or function. A natural or man-made event which could adversely affect the manufacturing process. A lapse in production for two years or as specified from the customer.

The Quality m anager s hould review or verify t he following i tems during t he Fi rst A rticle Inspection:    

Review t he m anufacturing p rocess sh eets to i nsure al l oper ations were co mpleted as planned. Review t he i nspection dat a, t est dat a, ac ceptance test pr ocedures, e tc. w here applicable. Review APQP Form 6.9 Open Issues Log for any nonconformance and their completion. Review the material certifications for compliance, as applicable. Issuing Dept.

Officer

Manufacturing

Established 01/19/09

Revision

Rev: Added new procedure

Rev #

Release

138

PROCEDURES MANUAL MANUFACTURING (Section 6) 6.9

First Article Inspection (continued)    

Verify t hat app roved S pecial P rocess sources were use d ( as applicable) and that t he process sheets called out the correct specifications. Verify that key Characteristic requirement have been met as applicable. Verify that part specific gages and/or tooling are qualified and traceable, as applicable. Verify that every required design characteristic is accounted for and identified with inspections results that are traceable to the design.



The quality m anager w ill not al low Fi rst A rticle I nspections to be co mpleted unt il al l non conformances and corrective actions are closed that affect the part.



These non-conformances shall be l isted in the Project APQP Plan Form 3.3.5 Open Issues Log and marked closed.



Non-conformances identified du ring the First A rticle I nspection m ust be co rrect and t he affected articles must be reassessed.



First Article Inspections shall verify all Design Requirements per the released FAA approved data where applicable. Results are to be recorded on First Article Inspection Form 6.9b unless they are noted as reference only.



Characteristics not measurable in the final product can be v erified by destructive means or during the m anufacturing pr ocess as long a s they ar e not a ffected by su bsequent operations.



Subassemblies or pr oduction pr ocess verifications should be r ecorded on t he asse mbly report form.



Units of measure that are specified on each design requirement shall be used to report to the same level of significant figures using indelible ink or electronic entry.



If t he desi gn r equires a vi sual or m echanical “ go or no -go” v erification or acce ptance i s verified using approved tooling then report Pass or Fail on the report form.



Records shall be m aintained according to the Document Control Procedure 7.2 unless the Customer or a regulatory requirement necessitates a longer period.

139

PROCEDURES MANUAL MANUFACTURING (Section 6) RELATED DOCUMENTATION [appendix] Form - First Article Inspection Form 1 – Part Number Accountability 6.9 Form - First Article Inspection Form 2 – Raw Material, Special Process and Functional 6.9a Form - First Article Inspection Form 3 – Characteristic Accountability, Verification & Compatibility Evaluation 6.9b Procedure – Manufacturing Process Plan Phase – Aerospace Section 3.8.5 Procedure – Document Control Section 7.2

Issuing Dept.

Sales / Program Management

Officer

Established 09/05/00

Revision 10/01/06

Rev: Revised for new ISO standard.

Rev # 001

140

PROCEDURES MANUAL MANUFACTURING (Section 6) 6.10 Intermediate and Final Inspection PURPOSE This procedure pr ovides specific instructions for t he i ntermediate and final o f i nspection of finished products controlled by a First Article Inspection process. SCOPE Proper Group International RESPONSIBILITY The quality department has overall responsibility to adhere to this procedure. PROCEDURE 

Quality associates will ensure that only calibrated tools, gages, and test equipment are used when performing in process checks or verification during the inspection process.



Quality associates will also ensure that all previous operations, inspections, and tests have been completed as indicated.



The quality manager distributes and assigns a stamp to each quality associate. A Master Quality Stamp Log Form 6.10 is kept with the associates name and the number that is assigned to them.



In-process inspections will be per formed by a quality associate as required by the Work Order Router Form 3.8.5.



The router sheet will be st amped with the quality associate’s stamp and dated to document the inspection has been complete.



All pr oducts not m eeting t he i ntermediate i nspection w ill be co rrected and r e-inspected before continuing to the next stage of the process.



Items that can not be corrected 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 router at each inspection interval.

Issuing Dept. Manufacturing

Officer

Established 01/19/09

Rev: New Procedure and Forms

Revision

Rev #

Release

141

PROCEDURES MANUAL MANUFACTURING (Section 6)

6.10 Intermediate and Final Inspection (continued) 

Final inspections will be performed by a Quality associate as required by the Work Router Form 3.8.5.



The router sheet will be st amped with the quality associate’s stamp and dated to document the inspection has been complete.



All pr oducts not meeting the final i nspection w ill be co rrected and r e-inspected o r w ill 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 router at each inspection interval.

RELATED DOCUMENTATION [appendix] Form – Work Order Router 3.8.5 Form – Master Quality Stamp Log 6.10 Procedure – Incoming / In Process Components & Material Inspection & Non Conformity Guidelines Section 6.2 Level 1 – Identification and Traceability Section 7.5.3 Stamp – Quality Checked & Approved By Tag – Non Conforming

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PROCEDURES MANUAL ALL DEPARTMENTS (Section 7) 7.1

Record Retention and Control

PURPOSE To establish a pr ocess 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 r esponsible for the areas or activities where quality m anagement r ecords are g enerated and stored are responsible to assure they are handled in a way that complies with this procedure. PROCEDURE 

All r ecords completed to dem onstrate co mpliance w ith t he P roper 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 appr oval of t he di sposition at t he meeting, t he records will be del ivered t o a t hird par ty r ecord disposition company for shredding within 30 days of the approval.



All r ecords are av ailable f or r eview b y cu stomers and r egulatory aut horities in acco rdance w ith t he contract or regulatory requirements.

Issuing Dept.

Corporate Quality & Development

Officer

Established 10/01/06

Revision 12/15/08

Rev: Updated to new company name and added Aerospace meetings.

Rev # 001

143

PROCEDURES MANUAL ALL DEPARTMENTS (Section 7) 7.1

Record Retention and Control Record

Location

Retention Min 3 Years

Max 5 Years

Responsibility

Management Review Reports

Corporate Development Files

Annual Internal Audit Schedule

Corporate Development Files

3 Years

5 Years

Corporate Development

Internal Audit Results & Internal Audit Reports

Corporate Development Files

3 Years

5 Years

Corporate Development

Training Records

Human Resources Files

3 Years after Termination

Human Resources & Supervisor

Calibration Records

Quality Files

As long as employed at the PME Companies 10 Years

12 Years

Quality

Mold Inspection Reports

Quality Files

3 Years

4 Years

Quality

Component Inspection Records

Proper Aerospace

10 Years from Shipment

Quality

8D Concern Analysis Reports & Matrix

Corporate Development Files

2 Years

13 Years after Shipment 4 Years

Mold Designs & Surface Files

Engineering & Data Management Proper Tooling

Product Data & Surface Files

Proper Aerospace

Customer / Program Management Files

Proper Tooling

6 Years (if operating system is supported) 10 Years from Shipment 3 Years from Ship Date

Customer / Program Management Files

Proper Aerospace

Data Management Records

Proper Tooling Proper Technologies

10 Years from Shipment 3 Years

9 Years

13 Years 5 Years after Ship Date 13 Years after Shipment 5 Years

Corporate Development

Corporate Development Engineering & Data Management Department Engineering Sales Program Management Sales Program Management Data Management

144

PROCEDURES MANUAL ALL DEPARTMENTS (Section 7) 7.1

Record Retention and Control Record

Location

Retention

Responsibility

Purchasing Files & Purchase Requisitions

Proper Tooling

Min 5 Years

Estimating Quotes & Packages

Proper Tooling

3 Years

4 Years

Proper Quality Management System Level 1 Policy Manual

Corporate Development Files

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 Corporate Development Files

Until Expires

Corporate Development Corporate Development

Corporate Development Files Corporate Development Files Corporate Development Files Corporate Development Files Corporate Development Files

Until Expires

Aerospace Standard

RELATED DOCUMENTATION [appendix] 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

Max 7 Years

Purchasing

Estimating

Corporate Development Corporate Development Corporate Development Corporate Development Corporate Development

145

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 p rocedure/form i s then forwarded t o an o fficer o f the co mpany for r eview, an y r evisions and approval.



The procedure / form is returned to the document control representative for distribution.



The P rocedure D istribution For m 7. 2 i s filled out for t he new or r evised pr ocedure/form. A ll P roper 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:

Issuing Dept.

All Departments

Officer

Established 09/05/00

Revision 03/06/09

Rev: Added procedure effectiveness review

Rev # 003

146

PROCEDURES MANUAL ALL DEPARTMENTS (Section 7) 7.2



Document Control 

The document control representative updates the Standards directory on the company network with the updated procedure/form. A n 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 i s maintained by the docu ment control representative t o ensure that the l atest revision is being used.  All approved docu ments hav e a r ed “ controlled co py” i n t he l ower r ight co rner. The or iginal 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 asso ciates. It is also the m anaging 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 t he new pr ocedure / form r eplaces a pr evious procedure/form, i t i s indicated on t he P rocedure Distribution Form 7.2



The P rocedure D istribution For m 7. 2 al so i ndicates which forms become obso lete and must be attached to this form and returned to the document control representative. It is also indicated on the Procedure D istribution F orm 7. 2 o f t he P roper Group International P rocedure M anual t hat al l files saved in other directories must be del eted. I t 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.

147

PROCEDURES MANUAL ALL DEPARTMENTS (Section 7) 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.

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] 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

148

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 pu rchasing depar tment has overall r esponsibility f or adher ence t o this procedure. R esponsibility f or manufacturing job, non-job & administration purchases are outlined in the purchasing & approval guidelines (Purchase Requisition Form 8.1). A ny associate may fill out a r equisition and r equest 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 app roved Purchase Requisition Form 8.1. This form is filled out for the i tem r equired i ncluding t he v endor na me, ch arge t o di vision, and t he per son r equesting the purchased products. Time and m aterial type purchases must also have an est imate 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, i f appl icable, sh ould be l isted on t he P urchase R equisition For m 8. 1. T he pur chasing 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 appr oved eq uipment pur chase or der m ust be se nt t o t he o fficers in ch arge of ope rations 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.

Issuing Dept. Purchasing

Officer

Established 09/05/00

Revision 08/07/10

Rev #

Rev: Updated Job relates approval signatures, & job titles for approval, chged Form 8.1

007

149

PROCEDURES MANUAL PURCHASING (Section 8) 8.1 

Purchasing Guidelines (continued) Any per sonal i tems purchased t hrough t he co mpany m ust be app roved by a g eneral manager or an Officer o f the C ompany. T erms of r epayment o n per sonal pur chases will be base d on t he f ollowing schedule:  Work Related: 25% per week  Non-Work Related: Personal purchases will not be allowed

Purchasing Guidelines - Manufacturing 

Manufacturing pu rchases fall under two ( 2) m ain ca tegories; job r elated ( ie: di e bl ocks) and n on-job related ( ie: cutting fluid). A P urchase R equisition For m 8 .1 must be filled out co mpletely f or al l 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. A fter 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 P lant Manager / Plant M anager / 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 pu rchases ar e t o be expedited, t he l ower “ initial for E xpedited P ick Up or D elivery” on P urchase Requisition Form 8.1 must be i nitialed 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

150

PROCEDURES MANUAL PURCHASING (Section 8) 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 est ablish a bl anket p urchase or der nu mber: co mpletely f ill out a Purchase R equisition For m 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 P urchase Requisition Form 8.1, check the blanket PO box and put the blanket PO # on t he PO # l ine. T he 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 appr oved and si gned by an O fficer of t he C ompany al ong with a co mpleted P urchase 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 r epair vendors who perform work at a P roper Group International facility must provide PGI with proof of work compensation and liability insurance. This insurance information should be attached to t he new v endor appr oval f orm pr ior t o submission for app roval. ( see I nsurance R equirements 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 o f pr operty caused by or ar ising from any and al l oper ations carried on or any and al l work performed under the Agreement.

151

PROCEDURES MANUAL PURCHASING (Section 8) 8.1

Purchasing Guidelines (continued)

Workers Compensation 

Statutory Coverage. Including occupational disease, if and as required, in a separate act. Coverage should al so i nclude an al l-states endorsement and em ployer’s liability C overage B . M inimum l imit required: $500,000 / $500,000 / $500,000

Commercial General Liability Insurance 

Policy t o i nclude pr emises & oper ations, pr oducts – completed oper ations and bl anket co ntractual 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) Products – completed operations aggregate Personal and advertising injury limit Each occurrence limit

$ 1,000,000 1,000,000 1,000,000 1,000,000

Automobile Liability 

To include owned, non-owned and hired vehicles. Minimum limits required:

Combined Single Limit   

Bodily Injury Property Damage

$ 1,000,000 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 / S ubcontractor / Outside P arties must furnish, not l ater t han t he time o f si gning of the Agreement, pr operty exe cuted C ertificates of I nsurance and, i f r equested, sh all f urnish P roper Group International with copies of the policies with all endorsements prior to the commencement of any work hereunder, i ncluding a c opy of t he contractual i nsurance endor sement i nsurance per formance o f t he Indemnity clause included in the Agreement.

152

PROCEDURES MANUAL PURCHASING (Section 8) 8.1



Purchasing Guidelines (continued) Subcontractors I nsurance C overage – if any of t he w ork to be per formed under t he terms of t he Agreement is awarded to a subcontractor by the Vendor / Subcontractor / Outside Parties, such subcontractor shall meet t he insurance requirements normally and reasonably obtained by such subcontractors.

RELATED DOCUMENTATION [appendix] 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

153

PROCEDURES MANUAL PURCHASING (Section 8) 8.2

Vendor Guidelines

PURPOSE This procedure provides specific instructions for the content, initiation, updating, revision and m aintenance of the approved supplier list. SCOPE This procedure encompasses all purchases made throughout Proper Group International. RESPONSIBILITY The pu rchasing depar tment and ac counting d epartment hav e ov erall responsibility f or adhe rence t o t his 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 For m 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. Issuing Dept. Purchasing

Officer

Established 09/05/00

Revision 03/20/09

Rev # 008

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

154

PROCEDURES MANUAL PURCHASING (Section 8) 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 i n S eptember, the acco unting depar tment r eviews the m aster v endor r eport. I f t here i s no activity for two years, the accounting associate sends the purchasing associate a l ist 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 obt ain 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.

155

PROCEDURES MANUAL PURCHASING (Section 8) 8.2 Vendor Guidelines (continued) Supplier Questionnaire 

To ensure the consistency of quality procedures, a q uestionnaire is sent to suppliers on a y early 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 co py of t heir cu rrent ce rtificate t o t he su rvey f orm and r eturn to P roper G roup I nternational’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 pur chasing asso ciate docu ments all co mments/notes on t he S upplier Q uestionnaire For m 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 act ions that are deemed necessary are documented on t he 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 S upplier Questionnaire For m 8 .2 and any associate docu mentation ar e filed al phabetically in t he purchasing department.



The Supplier Questionnaire Review Form 8.2a

Supplier Development 

The purchasing department monitors ongoing performance of the subcontractor to meet minimum requirements.

156

PROCEDURES MANUAL PURCHASING (Section 8) 8.2 Vendor Guidelines (continued) 

All printed purchase orders have the following notations on them: 

Proper Group I nternational ex pects 100% on t ime del ivery with vendors working t oward an equivalent ISO 9000 program. B y acce ptance of t his pur chase or der y ou as supplier a gree 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 t he pur chase or der m ust be pr ovided with each sh ipment or new lot of m aterial. Product w ill be r efused i f ce rtification i s not received with sh ipment or faxed be forehand t o the attention of shipping and receiving.



Per ISO 9000 requirements, al l quality r ecords and r elated do cuments m ust be maintained a nd 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 w ork with the vendors to improve their timing / quality. T he length of time to work the vendor will be at the purchasing associate’s discretion depending on individual situations.



The pu rchasing depar tment w ill co llect and su mmarize dat a for v endor and su pplier dev elopment to analyze that t he company’s goals for On-Time Performance, Costs and per cent AS or ISO certified suppliers are met.



These anal ysis are pr epared for r eview dur ing t he Q uarterly Management M eetings. 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.

(Reference

157

PROCEDURES MANUAL PURCHASING (Section 8) 8.2 Vendor Guidelines (continued)

RELATED DOCUMENTATION [appendix] 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

158

PROCEDURES MANUAL PURCHASING (Section 8) 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 g iven 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 pr oject takes longer than five weeks to build and i f timing is critical, timelines are required from the subcontractor.



The sch eduling asso ciate v isits the su bcontractor per iodically t o m onitor and v erify t he su bcontracted work if adequate electronic proof of completion has not been provided.



If there ar e any i ssues, a hi t l ist i s m ade up an d t he scheduling depar tment r eviews the pr oject. A n updated schedule is then generated if required. Issuing Dept. Purchasing

Officer

Established 01/16/01

Revision 02/01/09

Rev # 005

Rev: Form 8.3 is sent out only if req’d, subcontractors visited if req’d. Action Plan form omitted.

159

PROCEDURES MANUAL PURCHASING (Section 8) 8.3 

Verification of Subcontracted Product (continued) In t he ev ent the su bcontractor falls below t he P roper Group International S tandards, the V endor Guidelines Procedure 8.2 is followed.

RELATED DOCUMENTATION [appendix] 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

160

PROCEDURES MANUAL PURCHASING (Section 8) 8.4

Mold Construction Outsource

PURPOSE To manage, monitor, and verify subcontracted mold construction. SCOPE This procedure appl ies to al l desi gn, desi gn & bui ld, and bui ld onl y t o P roper Tooling pr ovided desi gn complete mold construction work outsourced by Proper Tooling. RESPONSIBILITY The program manager has overall responsibility for adherence to this procedure.

PROCEDURES 

After a subcontractor i s se lected t o per form mold desi gn and/ or co nstruction, a M old C onstruction 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 G roup I nternational. I t i s the p rogram manager’s responsibility to follow up and ensu re t hese weekly progress reports are received, and forwarded to scheduling.



If t he p roject i s behind sch edule, t he pr ogram m anager m eets with t he out source co mpany 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 t he ev ent t he su bcontractor falls below t he P roper G roup I nternational st andards, the V endor Guidelines Procedure 8.2 is followed. Issuing Dept. Purchasing

Officer

Established 05/20/02

Revision 02/01/09

Rev: Scheduling dept responsible for outsource schedule.

Rev # 005

161

PROCEDURES MANUAL PURCHASING (Section 8) 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 [appendix] 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

162

PROCEDURES MANUAL PURCHASING (Section 8) 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 co mpleted 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 [appendix] Form – Vendor Charge Back 8.5 Procedure – Incoming / In Process Components & Material Inspection & Non Conformity Guidelines Section 6.2 Issuing Dept.

Officer

Purchasing

Established 03/01/03

Revision 02/01/09

Rev: logo and name change

Rev # 002

163

PROCEDURES MANUAL 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 pi ctorial i nformation, el ectronic or paper, use d to m anufacture a m old, or use d for pr oduct 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 em ail will be s ent by data m anagement t o e stimating, as well as the appr opriate sales associate and pr ogram 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 co pied 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.

Issuing Dept.

Data Management

Officer

Established 09/05/00

Revision 01/19/09

Rev: Changed dept names to be current.

Rev # 007

164

PROCEDURES MANUAL 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 r eceived electronically will be st amped 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 un less 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.

165

PROCEDURES MANUAL 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 dat e. I t will be placed into the Quote directory.



The data management reviews the data for completeness. E ither 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 t ooling dat a m arked for job k ick off w ill be i dentified as status being “ NR”, r enamed 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 t he quote t ooling dat a ( part, pr int) sp ecified on t he q uotation ( if no t pr eviously completed). T he 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 O rder Fo rm 3.15 must be i ssued to ch ange t he st atus from “ NR” t o R eleased a nd be distributed with a copy of the original Data Request Form 9.1.



If a C hange O rder For m 3. 15 i s issued, t he three di git nu merical st atus will m atch the ch ange or der 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 bei ng N R, renamed i ncluding t he j ob nu mber, N R, file t ype, da te, and pl ace the file i n the j ob number part directory. Also, place the native part file in the part directory under the project job number.



When co mpleted w ith t he ov erlay, t he co mpleted D ata R equest Fo rm 9. 1 w ith al l at tached o verlay screen captures are to be forwarded to the data management and program management groups.

166

PROCEDURES MANUAL DATA MANAGEMENT (Section 9) 9.1 

Incoming Data & Naming Convention (continued) A C hange O rder For m 3.15 m ust be issued to ch ange the status f rom N R to r elease. T his Change Order Form 3.15 must include the engineering change data date only; and then distributed with a co py 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 r eceipt o f the D ata R equest For m 9. 1 an d t he assi gned p roject n umber, t he da ta m anagement group w ill m ove t he dat a ( retaining the original filename) from t he quote di rectory, t o a su bdirectory under the “ IN” su bdirectory ( using the o riginal dat e the da ta w as received as the folder na me, i e. ddmmyy) of the specific project directory.

167

PROCEDURES MANUAL 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. T his date cannot be changed, w ith t he ex ception o f files received on Fr iday a fter 3 :00 p .m. w hich will be dat ed as bei ng received on the following Monday.



The following nam ing c onvention will be adher ed t o f or al l i ncoming t ooling dat a. S ee ch arts 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 Customer File Name Customer

File Type (See Chart)

Part Name

Extension (See Chart)

Date (See Chart)

Released Part Files

3700L_C000_WR_05APR99.PRT

Job Status Date Number (See Chart) (See Chart) Left or Right File Type Extension Hand Data (See Chart) (See Chart) If Required Customer’s File Name

168

PROCEDURES MANUAL 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

Prefix (See Chart)

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

169

PROCEDURES MANUAL DATA MANAGEMENT (Section 9) 9.1

Incoming Data & Naming Convention (continued)

PREFIX p Proper ref

FILE TYPE NAME wr wo wi sr so si sc dt sd

PREFIX

DESCRIPTION Partial Data Proper Created Data/Revised Reference Data Vendor Abbreviation

EXTENSION NAME .cat .igs .prt .$ .3d .cad no extension _ck.prt .prt .elt .prt1

STATUS Not Released Release Change Order Number

DESCRIPTION Wireframe Only OSM Wireframe Only ISM Wireframe Only Surface Only OSM Surface Only ISM Surface Only Sections Only Wireframe, Surface, & Section Solids

DATE ABBREVIATION ABBREVIATION jan feb mar apr may jun

NAME nr c001 cxxx

STATUS

MONTH January February March April May June

ABBREVIATION jul aug sep oct nov dec

MONTH July August September October November December

170

PROCEDURES MANUAL 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 For m 9. 1 w ill be filled out by P roper T echnologies and a co py will be se nt t o t he t ooling program management group.



At this time, the Proper Group International Job Kick Off Procedure 3.6 will apply.

RELATED DOCUMENTATION [appendix] 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

171

PROCEDURES MANUAL 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 co re m anufacturing depar tment st andard t hat i ncludes manufacturing for al l di visions of P roper 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 nam e, descr iption, a nd a scr een dum p sh owing needed “ pick-up” d imensions for each file t hat i s 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 co mpletion o f C NC cu tting t he w orkpiece, t he m anufacturing asso ciate has the responsibility o f validating t he w orkpiece with X , Y , Z poi nt c hecks an docu menting t he ch ecks on t he M anufacturing Release Form 9.2 in the directory under the appropriate job number. Issuing Dept. Engineering

Officer

Established 03/01/02

Revision 02/01/09

Rev: Added further detail for the validation process on form 9.2

Rev # 006

172

PROCEDURES MANUAL 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” f ield o f 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 co mpleted by the core manufacturing department and a new Manufacturing Release Form 9.2 must be released.

RELATED DOCUMENTATION [appendix] 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

173

PROCEDURES MANUAL 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 depar tment will be responsible f or m aintaining and updating t he m aster f ile 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 T ransfer P rofile For m 9. 3 containing al l Proper Group I nternational customer dat a t ransfer information

Issuing Dept.

Data Management

Officer

Established 07/15/02

Revision 02/01/09

Rev: Updated directory location.

Rev # 002

174

PROCEDURES MANUAL DATA MANAGEMENT (Section 9) 9.3

Data Transfer Profile

Supplying New Customers / Vendors with PME Data Transfer Information 

Any t ime a new cu stomer or v endor r equests information on how t o t ransfer da ta w ith Proper G roup International, t he Data Transfer P rofile F orm 9. 3 filled out w ith t he P roper G roup I nternational data management information will be forwarded to the requester. File name: Form 9.3_Proper Group International.

RELATED DOCUMENTATION [appendix] Form – Data Transfer Profile 9.3

175

PROCEDURES MANUAL DATA MANAGEMENT (Section 9)

9.4

CAD Data Conversion Verification

PURPOSE This procedure de fines the pr ocess for v erifying C AD dat a accu racy when co nverted f rom a cu stomer’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 dat a co nversion v erification per t he cu stomer’s purchase or der or cu stomer’s standards. T he Project APQP Plan For m 3 .3.5 and C hange Order Form 3.15.5 will be used to communicate this need throughout t he or ganization. T he dat a m anagement depar tment i s responsible t o i nsure t his 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 w ill i dentify t he verification r equirement by ch ecking t he app ropriate box on t he C hange O rder 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. Issuing Dept.

Data Management

Officer

Established 01/19/09

Revision

Rev #

Release

Rev: New Procedure & Form

176

PROCEDURES MANUAL DATA MANAGEMENT (Section 9) 9.4

CAD Data Conversion Verification (continued)

 If t he co nverted dat a m eets the t olerance, t he D ata V erification For m 9.4 sh all be co mpleted with t he name of the person approving the files, dated and sa ved in the project folder. T he 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 p rogram manager will be not ified o f the rejection and the co nverted dat a sh all be del eted. N onapproved data can not be released to manufacturing. RELATED DOCUMENTATION [appendix] Form – Project APQP Plan 3.3.5 Form – Change Order 3.15.5 Form – Data Verification 9.4

177

PROCEDURES MANUAL CONTROL PLAN-FMEA (Section 10) 10.1.5 Manufacturing Control Plans PURPOSE The m anufacturing o f c omponents controlled b y t he Fi rst A rticle P rocess require a pr ocess control pl an. The control plan will be documented in the form of a Work Order Router Form 3.8.5. SCOPE Proper Aerospace RESPONSIBILITY Manufacturing / en gineering w ill cr eate a w ork o rder router t hat i nsures customer r equirements 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 [appendix] Form – Work Order Router 3.8.5 Procedure – First Article Process Section 6.9 Level 1 – Measurement, Analysis & Improvement – General Section 8.1

178

PROCEDURES MANUAL CONTROL PLAN-FMEA (Section 10) 10.1

Tool Construction Control Plans

PURPOSE All ne w pr oduction t ooling requires a generic control pr ocess plan. This procedure ou tlines 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 m anager o f m anufacturing al ong w ith a cr oss functional t eam i s responsible for maintaining and updating the generic Tool Construction Control Plan Form 10.1. P roject 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 t hroughout t he l ifetime o f the pr ogram ar e t o be docu mented by t he g eneral m anager o f 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 pr oject sp ecific control pl an i s then ca rried f orward ut ilizing t he M anufacturing P rocess Plan P hase Procedure 3.8.



If r evisions are not r equired, t he general m anager o f m anufacturing r eviews the T ool C onstruction Control P lan For m 10 .1 once pe r y ear and a revision dat e i s added showing a r eview has been completed.

RELATED DOCUMENTATION [appendix] Form – Tool Construction Control Plan 10.1 Procedure – Manufacturing Process Plan Section 3.8 Level 1 – Measurement, Analysis, & Improvement – General Section 8.1

Issuing Dept.

Control Plan / FMEA

Officer

Established 01/01/01

Revision 02/01/09

Rev: updated with new logo and company name

Rev # 004

179

PROCEDURES MANUAL CONTROL PLAN-FMEA (Section 10) 10.2 DESIGN FMEA PURPOSE 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 FM EA For m 10. 2 once per y ear and a r evision dat e i s added sh owing a r eview has been completed.

RELATED DOCUMENTATION [appendix] 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

Issuing Dept.

Control Plan / FMEA

Officer

Established 01/01/01

Revision 02/01/09

Rev # 005

Rev: items controlled by first article process will not be designed by Proper Group International

180

PROCEDURES MANUAL CONTROL PLAN-FMEA (Section 10) 10.3

Process FMEA

PURPOSE All ne w pr oduction tooling requires a generic process FMEA. This procedure ou tlines 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 m anager o f m anufacturing al ong w ith a cr oss functional t eam i s 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 P rocess FMEA Fo rm 10. 3 i s used for all ne w pr oduction t ools. A ny m odifications 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 Fo rm 10.3 i s used i n the manufacturing p rocess pl an m eetings as reference (Reference Manufacturing Process Plan Phase Section 3.8).



A pr oject sp ecific control pl an i s then ca rried f orward ut ilizing t he M anufacturing P rocess Plan P hase Section 3.8.



If r evisions are not r equired, the general m anager o f m anufacturing and t he cr oss functional t eam reviews the Process FMEA Form 10.3 once per year and a revision date is added showing a review has been completed.

RELATED DOCUMENTATION [appendix] 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

Issuing Dept.

Control Plan / FMEA

Officer

Established 01/01/01

Revision 02/01/09

Rev: updated with new logo and company name

Rev # 005

181

PROCEDURES MANUAL 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.