The procedures outlined in this manual explain the application of quality control and inspection methods according to established and approved procedures including military specification MIL-I-45208A Inspection System Requirements, ANSI/NCLS Z540-1-1994 Calibration Laboratories and Measuring and Test Equipment.. 

1.0 GENERAL

1.1 Introduction
This manual has been prepared by the Quality Control Department of Circuit Technology Center, Inc. This manual has been written as a guide for those concerned with the policies and procedures covering the quality control of parts and assemblies.

The Quality Control Department, through its suitably located inspection stations and apparatus essential to inspection, is responsible for complying with the requirements of this document.

Contracts and agreements are reviewed by responsible supervision for quality control requirements.

In order to facilitate the repair, rework, modification and assembly of circuit boards and assure conformity to standards and specifications, pertinent inspection operations are established in the following paragraphs. This manual is issued to all department heads, and to all inspection and quality control personnel. It is also issued, upon request, to our customers and to vendors performing critical processes or manufacture.  

1.2 Quality Policy
It is the intention of Circuit Technology Center to repair, rework, modify, assemble and deliver products having the highest level of quality and performance. To support this objective, the Company recognizes that the responsibility for quality is shared by all segments of the organization and that a single standard of quality control for all of our customers is most effective. 

1.3 Training
The resultant quality and reliability of modified or repaired printed boards and assemblies is highly dependent upon the skill and competence of the person performing these tasks. The implementation of proper methods by unqualified personnel can result in a substandard end product. Consequently, achieving successful results is predicated on the use of properly trained personnel whose skills have been tested and certified to be of a sufficient level of competence. See Employee Training and Certification records for each employee.

At Circuit Technology Center, an in-depth training program has been established to meet our objectives of quality and reliability. Each trainee is selected based on their manual dexterity, level of eye acuity, sound reasoning capability, and industry experience. Their training program includes review of our Quality Manual, all related aspects of our Guidebook, the IPC 7721 "Repair and Modification of Printed Board and Electronic Assemblies”, and IPC 7711 "Rework of Electronic Assemblies", published by the IPC.

1.4 Degree of Inspection
Inspection of many characteristics, operations and functions is performed 100%, otherwise inspection is performed to Circuit Technology Center sampling plans unless otherwise required by customer contract.  

1.5 Revisions
This manual shall be reviewed annually. Changes to this manual shall be made only with the written approval of the President. 

1.6 Ozone Depleting Substances
Effective 01/01/93 Ozone Depleting Substances (ODS), as defined by the US government, shall not contact any customer product or be used in the manufacture of any Circuit Technology Center product. All suppliers of Circuit Technology Center must also comply with this requirement. 

2.0 ORGANIZATION 

2.1 Quality Manager
Responsibility for the overall operation of the quality program is assigned to the Quality Manager. 

2.2 Chief Inspector
The Chief Inspector is responsible for the direct supervision of those persons engaged in Receiving Inspection, In-Process and Final Inspection. 

2.3 Organization Chart
The following depicts the quality control organization and its position within the company. 

2.4 Purchased Parts Flow Chart
The flow of materials through the various operations and inspection stations is shown on the following chart.

 2.5 Customer Product Flow Chart
The flow of customer product through the various operations and inspection stations is shown on the following chart.

To properly track orders which require repair, whenever possible, the part number and serial number are recorded and listed on the Circuit Technology Center service schedule which is used to assign technicians to each aspect of repair. If this is not practical, a separate serial number list is kept with the sales order hard copy as opposed to listing the numbers on the sales order form itself.  If specified, serialized repair labels may be attached to printed circuit boards or their attendant enclosures.  Large modification projects without serialization will be processed in bulk.  In these cases, to facilitate tracking, the customer and Circuit Technology Center may agree on a method to mark bulk orders.

3.0 SPECIFICATIONS AND CHANGE CONTROL 

3.1 Responsibilities
Process Specifications are distinquished from published Repair Procedures.  They are either customer specific procedures or unusual processes that, due to their nature, are not designated for general publication in the Repair Procedures portion of the company website. The specification system is operated by Engineering. Process Specifications are incorporated into the specification system by Engineering through the release of new specifications (ECNs) or changes to existing specifications.

Prior to the release of Process Specifications or Repair Proceedures for use, a review is made by Quality to ascertain conformity to applicable industry standard quality provisions. Copies of new and revised specifications are distributed to affected personnel and old copies are removed and destroyed at the same time. 

3.2 Engineering Release
Many specifications and documents are formally released using the form entitled "Engineering Change Notice" (ECN). All related specifications and documents are released at one time whenever possible. The ECN number is shown on each document. Original copies of both the specifications and documents, and the ECN are filed in Engineering. Once a specification or document is released it remains active for production unless otherwise limited, revised or made obsolete. 

3.3 Engineering Change Notice
Changes to existing controlled specifications and documents are affected through the use of Engineering Change Notices. This form describes the change to be made, the reason for it, and the effect, interchange, and disposition of parts. The ECN bears the applicable specification number, revision letter, and date. 

4.0 CONTROL OF MEASURING EQUIPMENT 

4.1 General
The Quality Control Department shall be responsible for maintaining a calibration system as described herein. They will also calibrate tools and gauges used for acceptance inspection or testing. This system shall also include the calibration of all standards used. See Calibration Record Index for a list of all calibration records.

4.2 Standards
The calibration of all reference standards shall be traceable to the National Institute of Standards and Technology.

4.3 Environmental Controls
Unless otherwise required, tools and gauges shall be calibrated, stored and used in ambient conditions of temperature and humidity.  All calibration and inspection shall also be done in a clean and well lit area. Should it become necessary to vary from the above ambient conditions during usage, consideration shall be given to measurement accuracy. 

4.4 Intervals of Calibration
All designated tools and gauges shall be placed on a schedule and calibrated at periodic intervals. The intervals shall be established as recommended by manufacturer, stability, purpose and degree of usage. The Quality Control Department shall review the results of previous calibrations and make changes in the intervals. They will be shortened or lengthened when the results of previous calibrations provide definite indications that such actions will assure continued accuracy of the system.  A listing of all items to be calibrated and their next calibration will be maintained on the Calibration Record Index so that upcoming calibrations will not be missed. 

4.5 Calibration Procedures
Written instructions from manufacturers and special written instructions will be used for calibration. 

4.6 Calibration Source
All calibration of reference standards and measuring equipment performed by an outside source shall be directed to do the following:

1. Calibration is certified as being traceable to the National Institute of Standard and Technology.
2. Calibration shall be supported by a certificate, report or data sheet with date, accuracy and conditions under which the results were obtained.

After equipment has been returned from calibration, Quality Control shall review the data received to determine compliance with the above requirements. 

4.7 Measuring and Recording
All calibration shall be supported by individual Calibration Records. The records will be so maintained to assure schedules are followed. The Calibration Record shall include the following:

1. Name and Number
2. History
3. Accuracy
4. Calibration Interval and Due Date
5. Calibration Procedures
6. Latest Calibration Value where applicable
7. Notation of Repair or Adjustment
8. Signature 

If the measuring and test equipment is found to be out of tolerance, the calibrated equipment will immediately be removed from service. Management will determine if the out of tolerance condition is of a magnitude to affect the acceptability of the product. Management will also evaluate the impact of the out of tolerance condition by considering the time since the last calibration and the quantity of materials measured. Consideration will be given to corral all in-house materials and re-inspect for suspect conditions and if the seriousness of the situation so warrants, the receivers of suspect materials will be notified and requested to verify the materials and correct discrepancies or return the materials. 

4.8 Labeling
All applicable measuring, measuring standards and test equipment shall be labeled to indicate last calibration date, next calibration date, and by whom it was calibrated. When labeling is not practical, a coding system shall be used to reflect its status. 

4.9 Subcontractor Calibration
Subcontractors shall have a calibration system which essentially meets the requirements of this specification. 

4.10 Use of Inspection Equipment
Measuring, measuring standards and test equipment shall be made available for examination by our customers to determine conformity. When necessary, personnel shall be made available for their operation. 

4.11 Non Calibrated Equipment
Many in-house measuring devices are used for reference purposes only and do not require calibration.  

5.0 PARTS SAMPLING 

5.1 General
This section outlines the plan for parts sampling inspection. This plan is approved when appropriate for use at all Circuit Technology Center inspection points.  It is rarely applied to service work. 

NOTES:
1. "Acc" means number of defective parts allowed in sample for acceptance of the lot.
2. "Rej" means number of defective parts required in sample for rejection of the lot.

6.0 IDENTIFICATION OF INSPECTION STATUS 

6.1 Policy
The inspection status of parts in process and finished goods shall be identified through the use of inspector’s initials on , Repair lLabels / Tags, Travelors, and/or Packing Slips depending on the nature of the job or customer specifications.  The intent, whenever possible, is to be able to trace the repair or rework performed on a circuit board back to the technician(s) who performed the repair or rework. 

6.2 Control
Initials will be issued to inspectors on the basis of the first letter of their given name, middle name, and surname. Would there normally be a duplication of initials, the Chief Inspector will assign a different set of initials or a numbers to one inspector. Initials for all Operators and Inspectors are listed on the company intranet.

6.3 Types of Initialing
Initials with appropriate prefix shall be used for the following:

7.0 PRODUCTION INSPECTION 

7.1 General
The quality of repaired, reworked, modified or assembled circuit boards within the Company is controlled through initial, in-process, and final inspection of the parts against the applicable drawings and specifications. Written procedures, checklists and records are used for the various points of inspection. With the exception of lot contracts to rework or modify circuit boards, all units receive 100% incoming inspection.

The proper methods for handling circuit boards to prevent mechanical damage, contamination, Electrostatic Discharge (ESD) and Electrical Overstress (EOS) are covered by Repair Guide Number 2.1, Handling Electronic Assemblies. This specification covers protection measures that are in effect to protect all circuit boards from arrival through final shipment. 

7.2 Incoming Inspection
Upon receipt of customer products, except lot orders, whenever practical the serial numbers of all units to be repaired are registered. After this registration and / or labeling, an examination of the product is conducted to determine the repair process to be performed. The processes to be performed and the cost are properly recorded.

For lot orders received to be reworked, modified, or assembled, a sampling of the product will be examined to determine the processes to be performed. The processes to be performed will be recorded on the Sales Order and the materials will be segregated. For more complex procedures, Process Specifications or customer instructions will accompany the traveler as required. 

7.3 In-Process Repair / Rework Inspection
During the repair of circuit boards, various aspects of the process may be checked periodically by inspection to determine that the operation is continuing to produce acceptable quality parts. This in-process check will be conducted by an inspector who will randomly select parts for inspection.

When appropriate, the Inspectors initials will be printed / stamped on the repair label or traveler after each inspection.

In the event that in-process inspection discloses nonconforming parts, the operation will be stopped until machine setup or operator procedure has been corrected. If any product is rejected the inspector will have the defect immediately corrected. If this is not possible it will be segregated, initialed and held for Material Review disposition. 

7.4 Final Repair Acceptance
When all operations have been completed on a repaired circuit board the technician's initials will be printed on the sales order or traveler sheet * (whatever the order dictates), then each unit will be given a final inspection to determine that all characteristics are acceptable, that no damage has occurred to the finished product, and that all aspects of the repair exhibit acceptable workmanship. The inspector will then print their initials on the the sales order and/or traveler.

If any product is rejected the inspector will have the defect immediately corrected. If this is not possible it will be segregated, initialed and held for Material Review disposition. 

*There are a few customers who require extensive tag sign offs for their boards.  These tags stay with those boards for the life of the unit.  Typically those orders are processed under time-sensitive conditions.  In those instances it is counter-productive to require seperate sheets listing serial numbers, the tag alone suffices for rework tracking. 

7.5 Verification
Unless provided by the customer or otherwise specified, the primary guidelines used for verification include the following:

IPC-A-600 Acceptability of Pronted Boards
IPC-A-610 Acceptability of Electronic Assemblies

IPC-7095  Design and Assembly Process Implementation for BGAs
IPC 7711Rework of Electronic Assemblies
IPC 7721 Repair and Modification of Printed Boards and Electronic Assemblies
IPC-CM-770 Component Mounting Guidelines for Printed Boards
ANSI J-STD-001Requirements for Soldering Electrical and Electronic Assemblies

8.0 PREPARATION FOR SHIPMENT  

8.1 General
Units are prepared for shipment in accordance with standard company or customer procedure. The type of packaging required is transmitted to Quality Control by way of the work order or other authorized document. Packaging is performed by Shipping under the surveillance of Quality Control. Packaging includes wrapping, bagging, electrostatic discharge protection, cushioning and marking of container. 

8.2 Standard Procedure
When special customer packaging is not required, the procedure described herein will be used. Modifications to this procedure may be made by Quality Control when necessary to maintain adequate protection for the units.

Units will be clean and free from visible contamination prior to packaging. Containers will be marked with the Company name and address and sealed. The packing slip and related documents will be enclosed or sealed in a packing slip envelope.  Whenever possible, all customer product will be returned in the same packaging in which it arrived. 

8.3 Special Procedures
Units will be packaged to meet customer requirements when specified. In the event that special containers are required for shipment, they will be obtained and stored for use. Special marking stencils, tapes and other labels will be obtained as required. 

9.0 NONCONFORMITY CONTROL 

9.1 General
Customer items supplied to Circuit Technology Center for processing, which fail to conform to the applicable drawing or specification will be handled as described in this section except as may otherwise be required by customer contract. Similar treatment will be given nonconforming supplies which do not become a part of the end product, e.g. tooling and test equipment, in so far as such items affect product quality.  The administration of these procedures and the coordination of related activities is the responsibility of Quality Control. 

9.2 Identification
Nonconforming parts, whether found in receiving, in-process, or final inspection are identified as such and are segregated from acceptable parts. The nonconforming parts shall be designated that they are defective.  The nonconforming parts shall be held apart from acceptable parts while they are awaiting Material Review.  Nonconforming materials or parts shall be held until final disposition. 

9.3 Material Review
Material review authority for items will be exercised by a Material Review Board consisting of the Quality Manager, an inspector, Senior Salesman associated with the account, and the CEO. (At least two members shall be present.)  This Board will be convened whenever necessary to consider the acceptance of nonconforming parts. Decisions to scrap or rework to drawing requirements, nonconforming parts may be taken without formal MRB proceedings unless otherwise required by customer contract. Applicable records of all Material Review decisions are maintained for seven years. 

9.4 Disposition of Parts
Nonconforming parts which have been "accepted as is" by Material Review are returned to production channels. Parts to be reworked to drawing or specification requirements are returned to the technician for the rework. In the unlikely event the part is non-repairable, the circuit will be marked as such and the customer notified.

9.5 Corrective Action
Material which has been rejected is documented.

Determining the need for corrective action and the assessment of its effectiveness is the responsibility of Quality Control. Whenever possible, immediate on-the-spot corrective action is taken, especially for in-house deficiencies. In such cases, formal documentation may be waived by Quality Control unless otherwise required by customer contract. 

10.0 QUALITY CONTROL AUDIT PROGRAM 

10.1 General
The effectiveness of the quality control program, while subject to continuous evaluation through analysis of scrap, rework, rejections and returns, is also assessed yearly through an audit. The audit is conducted by Quality, Engineering, and the President in accordance with the procedure described in this section. 

10.2 Audit Procedure Areas
The audit is conducted in those areas of activity subject to quality control procedures and standards. In each area the audit will determine the following:

1. Quality of inspection work being performed.
2. Availability of applicable documents.
3. Familiarity of personnel concerned with applicable documents.
4. Adequacy of applicable documents for controlling quality.
5. Condition of quality control records.
6. Identification of inspection status of parts in area.
7. Condition of handling, storage and preservation of parts in area.
8. Training and certification status of applicable personnel.

Receiving Inspection will be checked for the following items in addition to those above:

1. Latest drawings and changes on file.
2. Proper size samples taken for inspection.

Production Inspection shall additionally be checked for:

1. Latest specifications on file.
2. Adequate frequency of in-process inspection.  

10.3 Audit Administration

1. Audit procedure forms and results are kept on file.
2. If required (most correction is completed during or directly after the audit) corrective Action reports are filed.