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TOP-CALIB: Calibration Control System

REV:04/15/09

SCOPE: This procedure covers the calibration control system for precision measuring instruments. Instruments2 to be used for ANY measurement affecting the quality of Trinity Forge products must be entered into the Calibration Control System6 and tagged with a current calibration tag

STEP

WHO

WHEN

INFO TO USE

WHAT TO DO

RESULTS
1 Any team member Before using any precision measuring instrument The calibration tag on the instrument and the Measuring Instrument Verification Log

At the start of the each shift:

1. Verify1 that each instrument and/or standard to be used is tagged with a current Trinity Forge "Calibration" sticker.

2. Verify each quality related measuring instrument2 that will be used during a shift;record the verification and all other pertinent information on the Measuring Instrument Verification Log; IF THE INSTRUMENT and/or STANDARD is DAMAGED, HAS AN EXPIRED CALIBRATION STICKER, FAILS TO ZERO, OR FAILS VERIFICATION AGAINST A CURRENT CALIBRATED STANDARD, SUBMIT IT IMMEDIATELY TO THE QC SUPERVISOR or CALIBRATIONS CLERK--DO NOT USE!!

 Only calibrated instruments are used for measurements that will affect the quality of manufactured parts
2 QC Supervisor or Calibrations Clerk Instrument(s) needs to be repaired or adjusted Verbal and/or visual information from any team member about the instrument(s) condition Submit the instrument(s) to Metrology. Initiate recheck per TOP-RECHK. Defective instrument(s) is submitted to Metrology. Recheck procedure is initiated
3 Any team member (typically QC Supervisor) Having any precision measuring instrument needing to be placed into the calibration system Personal knowledge Submit instrument to the Calibrations Clerk for an acceptance review. The instrument is submitted to the Calibrations Clerk for review
4 Calibrations Clerk Upon receiving a precision instrument for entry or update into calibration control system Request from submitter Calibrate the instrument per step 6. Perform the precision instrument calibration3 process outlined in step 6
5 Calibrations Clerk As instruments become due for periodic calibration or are submitted for calibration due to questionable performance Calibration log Collect all instruments that are due or that have been turned in by users for calibration; identify in calibration log any instruments that have been lost, discarded or taken out of service using Calibration Control System Instruments are accumulated and ready for calibration or disposition recorded in calibration log
6 Calibrations Clerk As instruments are submitted for calibration and as due dates make it necessary Calibration log; precision instrument manufacturer info file

Calibrate the instrument to standards traceable to NIST and record the readings in the Calibration Control System; for Quality Control Inspectors and others required to meet the SNT-TC-1A-8.2 Visual Acuity Standard, refer the individual to Human Resources for the necessary eye examination; magnaflux Inspectors are required to have training by a certified Magnaflux Inspector to maintain a Magnaflux Inspector Level II rating; furnace temperature controls are calibrated per TOP-BRKDN; perform any instrument adjustment as needed to bring the instrument within the acceptable limits for proper calibration; for an instrument that is the property of Trinity Forge, Inc. requiring advanced or extensive calibration, adjustment or repair, submit the instrument to an approved calibration vender capable of performing the required calibration, adjustment or repair per the ANSI/NCSL Z540-1-1994 standard and/or ASME-B-893 standard for software involved calibration, adjustment or repair;any personal instruments requiring advanced or extensive calibration, adjustment or repair will be returned to the owner for disposition; all transactions will be noted in the Calibration Log; cite applicable Federal specifications and tolerances along with required traceability to NIST; require a report on the condition of the instrument as received by the calibration vender.

 A pass or fail determination is made on the instrument. The Calibration Control System updated
7 Calibrations Clerk For any instrument failing calibration (including vender calibrations) that cannot be economically repaired Results of calibration Tag the defective instrument with a red REJECT label and make the appropriate entry in the Calibration Log; return personal or customer instruments to the owner; properly dispose of Trinity Forge defective instruments. Notify the supervisor(s) of affected area. Defective instrument is removed from premises
8 Calibrations Clerk For any instrument failing calibration (including vendor calibrations) that can be economically repaired Results of Calibration Notify the QC Supervisor. Repair instrument in-house, if possible or send to an approved calibration vendor per step 6 and initiate re-checking per TOP-RECHK; in the case of Visual Acuity failure, after corrective action is taken, refer to step 6. Defective instrument rechecking procedure initiated
9 Calibrations Clerk When an instrument passes calibration Results of calibration Decide on the next calibration date based on type, condition, environment, use of the instrument and recommended calibration frequency4; update the calibration log and tag the instrument with a calibration label showing identification, calibration date, next calibration date and the calibrator’s stamp; apply any safeguard to protect the instrument from adjustments that would invalidate the calibration; return the instrument to user with any recommendations. The calibrated instrument is tagged, logged, safeguarded from adjustments, and returned
10 Calibrations Clerk When a calibration date needs to be extended Calibration log or own judgment Calibration due dates may be extended by no more than one-half of its normal calibration period under circumstances deemed appropriate; note the extension and circumstances in calibration log. The calibration date is extended for the calibrated instrument and the calibration log annotated
11 Calibrations Clerk When instruments are not in use for extended periods or are missing Personal knowledge For an instrument that is not in use it may be tagged as “IA” (inactive), appropriately stored and noted in the calibration log; tools that are missing will be entered into the calibration log as such; a “Tool Status” e-mail is to be sent to the appropriate supervisor(s). All tools tagged inactive or are missing are appropriately disposed. The calibration log is updated and the affected supervisor(s) are emailed
12 Calibrations Clerk, Engineer, or Supervisor When an inactive ("IA") precision measuring instrument is needed Personal knowledge and the calibration tag on instrument Go to step 4 unless the Calibrations Clerk is not available; in the event that the Calibrations Clerk is not available, and a tool is needed in an emergency, a supervisor may temporarily activate the tool by doing a calibration per step 6. An email must be sent immediately to Calibrations Clerk. When the Calibrations Clerk becomes available, the tool will be submitted for proper calibration and entry into the calibration log. Calibrations Clerk calibrates and updates calibration control system
1 An instrument is verified by taking measurements at the lower 25% AND upper 75% (rounded to the nearest whole increment) of the measuring instrument's measurement range. After taking the above maximum measure, the measuring instrument must be returned to zero (0) point and the reading observed. All prescribed tolerances must be observed. Deficiencies including tip wear that may cause the instrument to measure incorrectly must be monitored.

2 Includes, but is not restricted to any existing calibrated and logged precision measuring device (caliper, CMM, v-block, micrometer, scale, fixture, gage etc), any precision measuring device not previously entered into the calibration system, any previously rejected precision measuring device that has been repaired, or any individual required by TOPS (QC Inspectors, Magnaflux inspectors, etc) to be entered into the calibration system.

3 Calibrations Clerk's calibrations are per ANSI/NCSL Z540-1-1994. Readings must be taken at the beginning point, mid point, end point and back to beginning point of each instrument with no greater than a three (3) inch increment between calibration points unless otherwise specified by the QA Manager. On calipers, tip-wear must be monitored by taking readings well into the jaws as well as near the beginning of the jaws. Tolerances for calipers and similar instruments are +/- .003 inches in the Forging Department and +/- .002 inches in the Machining Department. Tolerances for micrometers are to +/- .002 inches in Forging Department and +/-.0005 inches (with 10th graduations) or +/- .001 inches (without 10th graduations) in the Machine Department. Machine Department Gage Pins verification is +/-.0003. Exceptions, other instruments must be accurate to within 5% of the dimension tolerance interval of the dimension being measured. Exceptions must come from the QC Supervisor.

4 Calibration frequency is 12 months for CMM, Surface Tables, Master Blocks, CNC Machines, Thread Gages, and 1-5 years (based on usage) on Standard Blocks. Visual Acuity examinations will be given within the first ninety (90) days of hire date regardless of temporary or full time employment status. This testing is required for QC Inspectors, QC Leadman, Post Forge Workers that work on the inspection table,or anyone doing a visual inspection of a part as part of final review. This testing will be administered annually and the employee will be identified with an “Eyeballs” sticker and calibration date on their hard hat. Magnaflux Level II every 3 years. Calibration frequency on all other instruments is 6 months unless otherwise specified by the QA Manager.

5Calibration Control System includes but is not restricted to Quality Control, the Calibration Log, the Verification Log, and Gage Manager.

6 Current Trinity Forge calibration stickers include but are not restricted to Trinity Forge calibration stickers and third party calibration stickers bearing a Calibrations Clerk signature or stamp.

7Flight Safety Requirements: All measurement and test equipment used to inspect Flight Safety Parts is discriminate to within ten percent (10%) of the total tolerance spread for the feature being inspected. For total tolerance spreads of less than .001 inch, measurement equipment is discriminate to within twenty percent (20%) of the spread. Equipment less discriminate is used with the specific approval of the customer.

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