(0APO19 Rev. N Page 1 of 8 aR01336, AERO > CONTRO Sebi AEROFLUIDPRODUCTS |222 Moni Bhd Sout Eusid OH 44321 213 Gilet Panel OM 44077 SAMPLE INSPECTION PLAN QAP019 Revised by: lan Hudgins Date: 3/31/14 ‘Approved by: Gary J. Peters, Date: 4/2/14 Released by: Wendy Sharp Date: 4/2/14QAPO19 Rev. N Page 2 of 8 REVISION PAGE rev Description - Date [By NR | New Release Sepi 2, 1955 ‘A _| Added to Scopes When required, the sample plan wil be submited to customers | Sep 11.2002 fer approval. Added t 6.7 (no nonconformance found insamplelot), Revised par. 3.0 to reflect UTC requirements. Completely evsed page removed | Mat 19,2008 Pratt & Whitney, and added United Technology Added new sample table Added al UTC participants and definitions for critical, majog and minor, € Par 6.9 ..with QAPOZ1 was:...with Section 4.13 of the Qualiy Manval Par.6 | Now, 23,3003 {orm 128A was 128 and QAPO34 was QAPO33, 7 2 ‘Added Honeywell to par. 3.0 Added page 9of 5 uly 25, 2065 G E Pat an joa for Fd Regulators | Nov. 2005 ws | Produces - F Reformattedentve document Added Sample Char to use for inspection ofheat | Wov2i, 2008 | GIP treat, Added Sample Chart fr Legacy “FRC” Products, _ __ ig Revised Sample Tables to clarify and reduce number of diferent sampling plans. | Wav, 2007 oP Sample plans designed to meet or exceed the customer specified requirement, Rel ‘aR005s8 ¥ ‘Added Visual inp and Visual for marking to Quay Panning Guidelines. Deleted | bee 17,2007 oF paragraph 7.12 Added note to Quality Planning on inspection of bulk or oll material, Ref. QRODSSE. T Revised Mechanical sampling Requirements, added Table 1, Sampling Chart snow | Mor26,2010 | GIP Table 2. Ref QROOBES. 7 Fix Rev. on page 7. Ref GRDOSTS.—___ Tay 24,2010 | WS be Deleted Para 6.0 Ref. ROLE ‘March 20,201 | wes L ror on fev of 2 pages. Ref. OR OI087_ Wo other chan ‘Mareh 23,2012 | WAS M Ret. QROL2S0, Rev. Para, 71,75. 7.11 was added, Removed signature page. Sep.30/2013 |W N ‘Revised Qualty Planning guidelines, added Table 3. See QROI336 forall changes. | March 31,2018 |10 20 30 40 QAPOIS Rev. N Page 3 of 8 scope This procedure/plan establishes the basic sampling plan that is used to inspect all tems delivered to and bby AeroControlex. The plan consists of inspection of all characteristics contained on the drawing for Receiving/Final inspection, and all characteristics contained on the drawing and/or process sheets and routers for In-Process Inspection. The plan is subject to change due to changes in customer requirements. \When required, the sample plan will be submitted to customers for approval RESPONSIBILITY ‘The AeroControlex Director of Quality and Manufacturing Services has the authority and responsibilty for the administration of this procedure. All personnel that perform final inspection of product at ‘AeroControlex are responsible for compliance with, and implementation of, this procedure. Quality Assurance is responsible for the development and maintenance af all sample plans in accordance with this procedure. APPLICABLE DOCUMENTS ‘This document and associated tables has been created to meet the requirements ofthe folowing customers and specifications; Boeing D1-8007 F, United Technologies ASQR-20.1 and Honeywell SPOC- 128. TERMS AND DEFINITIONS 2, Characteristic A distinguishing feature on which variable or attribute data can be collected. b. Defect Any deviation from drawing requirement © Lot ‘The units of product from which the samples selected 6. Sample ‘The units selected at random from the entire lot & Random Sample ‘Asample selected in such a manner that each part in the lot has an equal chance of being selected. Through traning, all personnel that perform final inspection are knowledgeable in random sample selection, f. Inti Reliability Requirement (IRR The expected reliability ofa part as tis delivered tothe customer. Operationally, itis the fraction of units of product that must conform to requirements before the suppliers eligible to ‘perform acceptance sampling. The IRR also provides a bass or the continuing level (amount) of sampling. & Acceptance Number The maximum number of defective items in the sample that will permit acceptance ofthe entire lot, For AeroControlex, number is era (0). h. Rejection Number ‘The smallest number of defective items in the sample that will require rejection ofthe entire lot For AeroControlex, number is one (1). Rejected Alot that cannot be accepted based on the results of acceptance sampling due to the number of defects found within the sample,50 70 QAPOI9 Rev. N Page 4 of 8 i sampling Plan ‘The instructions given to the personnel performing acceptance sampling. Consider this procedure the Sampling Plan. Sampling Procedure The policy governing acceptance sampling. From this procedure 2 sampling plan can be developed. TRAINING All personnel that perform final/receiving inspection shall be trained in the proper use of this procedure. ‘The training shall consist of: sampling philosophy, use ofthe sample tables, random selection of parts, and record keeping. Refresher traning shall be conducted when retraining is required. Records of ‘raining shall be maintained, Paragraph 6.0 was deleted. PROCEDURE 7.1 Determine the lot size (number of pieces) submited for inspection, An acceptable FAlis required before sampling inspection can be applied 7.2 Determine, per the guidelines, the IRR for characteristics to be inspected, 7.2. Tolerances 0003 or less require 100% inspection (Class AA 7.22 Major Characteristic Dimensional Tolerances equal 010 inch or less and any characteristic classified as major by 8/? or specification. 9796 RR (Cass A) 7.2.3. Minor Characteristic Dimensional Tolerances equal or greater .0101 inch and all characteristics not classified. 959 RR (Clas 8). 7.2.4 Specifications that are not measurable characteristics, |e. anodize, passivation, ete, shall be Inspected by review of documentation, 7.3 Determine the proper sample size for the lat from the sample table, 7.4 Randomly select the sample from the entre lot 7.5 Inspect the sample using appropriate inspection methods and techniques. Additions or ‘exchanges to the original sample are not permitted, under any circumstances, 7.6 The results (A/R) shall be recorded on the Inspection Record 7.7 The lot shall be accepted if ll characteristics conform to requirements (ne nonconfermance found in sample ot), The conforming lot is stocked or sent for further processing, 7.8 Ifinspection results indicate the parts do not conform to specifications, an Inspection Discrepancy Report (\DR), form 128A, shall be written in accordance with QAP 034, 7.9 The disposition of the material shall be in accordance with QAPO21. 7.10 Sample inspection shall be used for Receiving, In-process, and Final Inspections unless customer requirements dictate otherwise. 7.11 Sampling inspection is prohibited for characteristics affected by rework or repair eispostions,(QAPO19 Rev. N Page 50f8 ‘QUALITY PLANNING GuIocuNEs ‘ASS [TOTAL TOLERANCE | SURFACE Nis [ ANGLES THREAD [Heat Treat TA/crtcal | 0003 or Less 5 5 5 - ‘AMajor 0004-010 Solas | iDegree ortess | — Cass 5 ‘Minor [Greater then Gi0 | 33 orRigher | ~ Over Degree | Chass? E c Havana iechanial Sampling Requirements ‘Dim. Total Tolerance Range ess than or equal 0,008 inches - me Radiless than 010 inches Total Tolerance Range 65% Angle Total Tolerance Range less than or equal to 1 degree - 65% [Surface Finish Waviness —_— 65% Surface Finish Roughness (Ra) less than or equal to 20 micro inches 65% Threaded parts + Internal Profle Pre-load Locking 65% {straight screw threads ~ total tolerance on itch dameter 55% + ANE MS parts or MH electrical connectors 15% © Allother thread applications/characteristics 65% Splines (all characteristics) — 65% Gears (all characteristics) 65% Absence of magnetism ox Spring Rate - 55% Visual Inspection See Table 1 for Guidance _ 100% Visual Inspection (for Marking) See Table 1 for Guidance 100% ‘Specific customer requirements take precedent over this table, ‘Material purchased in roll or by volume shall not be sample inspected. When inspecting material such as race ‘material, core material or wire, a suficient number of feet will be evaluated to determine ifthe roll meets the ‘drawing specification. This may include the removal of several feet of material for special testing ‘Table 2is designed to meet UTC, Honeywell and Legacy ACK and FRC requirements. The table meets or exceeds sample sizes required by UTC and Honeywell Table 3's an alternative sampling table. This table can be used for in process operator inspections.Page 6 of 8 Table 1 ‘QAPO19 Rev. N { Viswal Requirement Sample Part Marking including serialization and acceptance symbols. 100% [Completeness of Assembly —_ _ — "100% Damage 100% | Existence of similar physical features 100% ~OSCSC~*~S: Orientation and Alignment 00% ‘Numbers of Bearings rallers/balls 100% Inspection of Locking installations 700% Welds of Braxes 100% Present of Sealant or Lubricants ~ 100% Presence of protective caps 100% Plating, Coating, Surface Treatment and Protective Finishes 100% Fuel holes and oll holes and passages 100% ‘Gleanliness| 700% Corrosion 100% “Rahesive Bond 100% Evidence of Staking 700% ‘Contamination and freedom of debris In internal passages 100% Radit ~ 100% ‘Surface Finish Cosmetic Appearance (e.g. scratches, fingerprints, uniform 100% SS(QAPO19 Rev. N Page 7 of 8 Table 2 Attribute, Accept on Zero (C=0) Sampling Plan Acceptable Quality Level (AOL) Percent Insp Level Code [aa] Classification [Critical | | tot size [rome eekoane 2 8 9 15 16 25 26 50 51 90 94 160 151 280 281 500 501 1200 1201 3200 3204 40000 40004 35000 35001 450000 480004 500000 3500000 * Changed to 21 to meet the Honeywell Requirements ** Changed to 6 to meet Hamilton Sundstrand Requirements, itis to be used for Major Dimensions on Hamilton Sundstrand DrawingsPage 8 of 8 Table 3 ie | Frequency 100% Inspection Required 100% Inspection Required [Every Third piece [Every Tenth piece [Every Third piece Every Fifth piece Every Tenth piece Every Fifteenth piece xlola|mlololl> [2 First Piece and after Tool Changes QAPO19 Rev. NRERO Cease é Subject: Subcontractor Inspection _Effective Date: July, 2004 QAP043 Requirements Page 4 of 10 Rev. H 1.0 PURPOSE 2.0 3.0 To establish a uniform method for the flowdown of inspection requirements to all subcontractors that perform work for AeroControlex. Additionally any specific requirements and sub-tier purchase order review must be complied with by all subcontractors performing work designated for Pratt & Whitney, Hartford. This additional requirement shall be specified on the purchase order. SCOPE ‘This procedure shall be adhered to by all subcontractors, with the exception of distributors of hardware, standard catalog items, and special processors other than heat treating. Monitoring will be done by AeroControlex Quality Assurance. PROCEDURE 3.1 First Article Inspection é 3.1.1 A First Article Inspection Report (F.A.LR.) shall be completed in accordance with AS9102 (latest revision) using form 1, form 2, and form 3 as necessary, including a bubbled drawing, and submitted to ‘ActoControlex with the shipment. The F.A.LR. consists of 100% documenting and inspection of all drawing characteristics, notes, processes, and other specifications or requirements. First Article Inspection shall be performed when: «© Anarticle is produced for the first time «The drawing has been revised (Delta F.A.LR. only). This shall consist of the revision(s) and features which are affected by the revision(s). ‘© Methods of manufacture have been revised that could result in a change to product configuration ‘+ Tooling used to produce parts has been transferred from one supplier to another or to another division of the same supplier. ‘+ Tooling used to produce parts has been repaired or rebuilt (DELTA FALR. only) ‘+ Two years have elapsed between production of an article (does not apply to castings, forgings, molded parts, :nmeplates, or any die- cut products). If stock or inventory is available from a previous FALLR, then a full F.A.LR. is required on the next production run, «Requested by AeroControlex Quality Assurance © Three years have elapsed since the last F.A.LR,99193-3880523-3 99193-3 9523-3 CDA-81833 CDA<. 833 O"'@ e “®) inci eg) a ooss.38b0503 30 99193-3880523-3 Coasi833 CDA-81833 150241 150241 99193-3880523-3 (CDA-81833, 150241 99193-3880523-3 (CDA-81833 150241 99193-3880523-3 CDA-81833 150241 99193-3880523-3 CDA-81833 150241 99193-3880523-3 CDA-81833 150241 99193-3880523-3, CDA-81833 150241 99193-3880523-3 CDA-81833 150241 99193-3880523-3 CDA-81833 150241 99193-3880523-3 CDA-81833 150241 99193-3880523-3 CDA-81833 150241 99193-3880523-3 CDA-81833 150241 99193-3880523-3 (CDA-81833, 150241 99193-3880823-3 CDA-81833, @u@) 99193-3880523-3 CDA-81833 150241 99193-3880523-3 CDA-81833 150241 99193-3880523-3 CDA-81833 150241 99193-3880523-3 CDA-81833 150241 99193-3880523-3 CDA-81833 150241 99193-3880523-3 CDA-81833 150241 99193-3880523-3 (CDA-81833 150241 99193-3880523-3 CDA-81833 a"@® 99193-3880523-3 CDA-81833 150241 99193-3880523-3 CDA-81833 150241 99193-3880523-3 CDA-81833 150241 99193-3880523-3 CDA-81833 150241 99193-3880523-3 CDA-81833 150241 99193-3880523-3 CDA-81833 150241 99193-3880523-3 CDA-81833 150241 99195 3886523-3 CDA-81833 aw 99193-3880523-3 CDA-81833 150241 99193-3880523-3 CDA-81833 150241 99193-3880523-3 CDA-81833 150241 99193-3880523-3 CDA-81833 150241 99193-3880523-3 CDA-81833 150241 99193-3880523-3 CDA-81833 150241 99193-3880523-3 CDA-81833 150241