US CASTINGS
PURCHASE ORDER NOTES (FORM PUR-3 REV. M)
NOTE MI 01
Parts manufactured on this order are from US Castings and do not require material test reports. The US Castings material number (seller received in P.O. contents) shall be identified on Certification of Compliance returned to U.S. Castings, LLC.
Supplier must provide a statement on their Shipping document certifying its quality assurance department has inspected the parts and they adhere to all requirements, applicable drawings/specification
NOTE MI 02
Any non-conformance from the requirements of the drawing, specification, delivery or Purchase Order requirements must be reported with cause and corrective action in writing. US Castings shall be alerted to non-conformances and departures to the stated requirements in writing. Disposition must be issued by US Castings Accepting nonconformance or departure prior to return. All non-conformances and departures shall be documented within shipping documents and the product segregated and identified as nonconforming.
Boeing Note:
The supplier Acceptance Test Procedure (ATP) is intended to provided reasonable assurance that a NEW part/component meets the minimum requirements for fit, form, and function for its intended use. The ATP is insufficient as a standalone investigation tool for a specific documented nonconformance, unless a step within the ATP specifically accounts for/test for the identified nonconformance. Supplier investigation of documented NON-CONFORMING product(s) must lead the supplier to “eliminate the cause(s) of the nonconformity, in order that it does not recur or occur elsewhere” (QMS AS/EN/JISQ 9100) or produce evidence that the supplier is not at fault.
NOTE MI 03
Alteration of material or process is prohibited unless specifically noted in the Purchase Order.
Boeing Note:
Supplier will not and will ensure its supply chain will not, initiate a movement or transfer of the location to be performed without USAC prior written approval. Notification must be prior to the manufacturing start date of the first part associated with the work transfer.
NOTE MI 04
Supplier is authorized to work to the drawings, ADCNs, sketches and specifications sufficient to inspect and/or test material listed on the Purchase Order. If any ADCNs or drawing revision changes the configuration or process of part and are not called out or drawing revision changes the configuration or process of part and are not called out on the purchase order, Seller shall notify US Castings immediately for written authorization.
NOTE MI 05
Seller is responsible to conduct 100% First Article Inspection. The supplier must list all drawing dimensions, tolerances and processes by specification number provided by drawing and/or Parts List. First Article verification to un-dimensioned drawing will require overlay of the part to a PCM. Center of lines defining parts as drawn on the PCM is considered nominal. Part acceptance to PCM can be recorded as part profile, leg profile, cap profile, etc. All inspections conducted to a Boeing print must be documented per the requirements of AS 9102.
NOTE MI 06
Seller shall implement statistical process control per AIAG SPC Manual Second Edition. Characteristics identified on this part do not require data to be gathered on this operation.
NOTE MI 07
Seller shall implement statistical process control in accordance with the intent of AIAG SPC Manual Second Edition Characteristics will be identified on purchase order. The characteristics will require the following actions:
- Documented measurement of key characteristics.
- Evidence of variation (X Bar and R Chart, histogram)
- Evidence of corrective action taken if a key characteristic is either not in control or not capable.
NOTE MI 08
A preliminary process capability study is required. Supplier is responsible for producing a minimum of 30 pieces inspecting, recording, analyzing and submitting a report.
NOTE MI 09
Seller must mark parts with Part Number, Date and Final Inspection stamp per requirement listed in P.O.
NOTE MI 10
Supplier must comply with Boeing document D1-4426 “Approved Process Sources” (http://active.boeing.com/doingbiz/d14426/index.cfm). This document, subject to revision from time to time, defines the approved sources for special processing, composite raw materials, composite products, aircraft bearings, designated fasteners, and metallic raw materials. The Supplier’s purchasing information must conform to the purchasing data requirements of Boeing documented D1-4426 Appendix D. These purchasing data requirements can be found at: http://active.boeing.com/doingbiz/d14426/Appendix-D.pdf
Controlled” or “Approved” planning requirements are derived from the part specific Engineering requirements. Planning changes to “controlled” or “approved” planning requires compliance with the associated processes prior to implementing proposed changes within supplier’s production system and commencing manufacture. Supplier must submit manufacturing planning changes to USAC in accordance with the requirements described within the associated process for approval/re-approval. USAC engineering qualification/approvals include material & process approvals and quality engineering approvals.
Supplier is required to notify USAC Purchasing Agent if procured item is manufactured at a Suppliers facility not reflected on the procurement document.
MI10E
Seller will utilize Eaton approved special processors whenever the purchase order identifies castings as Eaton product. Seller shall contact USAC before beginning work if they do not have access to the Eaton Approved Processors List.
NOTE MI 11
A Certification of Compliance is to accompany each shipment. The Certificate shall include:
- Part Number
- Drawing, Parts List and ADCN Levels
- US Castings Material Number
- Applicable specifications, revisions levels, amendments and PSD numbers.
NOTE MI 12
By accepting this order, seller certifies that it will maintain a quality and delivery system adequate to provide the supplies and services that meet the requirements of this Purchase Order, applicable specifications and/or engineering drawing. Supplier shall notify US Castings in changes in product and/or process definition and, where required, obtain US Castings approval.
By accepting this order, sell certifies that it will comply with all applicable environmental, health and safety laws and regulations in performance of work for US Castings.
Supplier shall maintain records of product, processes and services supplied for a minimum of remainder of calendar year plus 10 years or longer if designated on the purchase order. Once this retention period has been reached, the Supplier is responsible to contact US Castings for record disposition instructions.
Product, drawings and supporting documentation may contain technical data whose export is restricted by the Arms Export Control Act (Title 22, U.S.C. Sec 2751, et seq.) or the Export Administration Act of 1979, as amended (Title 50, U.S.C., app. 2401 et seq.) Violators of these export laws are subject to severe criminal penalties. This information in document form ( or any other medium), including any attachments and exhibits hereto, may not be exported, released or disclosed to foreign persons whether Recipient shall include this notice with any reproduced portion of product or provided documentation.
US Castings requires that supplier is to have work performed on their purchase order by competent personnel with the qualifications required of the drawings and specifications provided.
Supplier is responsible to ensure that all personnel affecting products and services provided on this purchase order are aware of:
- Their contribution to product or service conformity;
- Their contribution to product safety, and
- The importance of their ethical behavior.
US Castings requires that external providers apply appropriate controls to their direct and sub-tier external providers to ensure that requirements are met.
All applicable requirements, including all applicable statutory, customer and regulatory requirements, of this purchase order are to be flowed down the supply chain to point of manufacture.
To maintain Approved status with US Castings, supplier must maintain an on-time delivery percentage greater than 97% with a quality PPM of 3000 or less.
Supplier must maintain, and have available on a timely basis, quality records traceable to the conformance of product/part numbers delivered to USAC. Supplier must make records available to regulatory authorities and USAC authorized representatives. Supplier must retain records for calendar year + 10 years from the date of shipment under each applicable order for all product/part numbers unless otherwise specified on the order. At the expiration of such period set forth above and prior to any disposal of records, Supplier will notify USAC of records to be disposed of and USAC reserves the right to request delivery of such records. In the event USAC chooses to exercise this right, Supplier must promptly deliver such records to USAC at no additional cost on media agreed to by both parties. USAC requires that the provisions/requirements set forth above be included in Supplier direct supply contracts related to the Products/Part Numbers.
The Supplier must compile and maintain a single source of documented information and refer to it as a Quality Manual. The Quality Manual must include a description of the quality management system and contain or make reference to the documented
Supplier must ensure that all of the control activities listed within the AQMS standard are applicable and addressed within the Supplier’s processes for control of documented information.
The Supplier must ensure their internal processes address the use of Customer/Engineering authorized manufacturers and/or designated sources (e.g.; Qualified Product List {QPL}) and they must ensure retained documented information is validated prior to the release of products and the documented information includes traceability to the designated source.
Supplier will comply with and flow down to its Supply Chain the requirements of Boeing Form X38656, “Advanced Product Quality Planning (APQP) & Production Part Approval Process (PPAP)”.
NOTE MI 13
Seller shall, prior to beginning work, contact US Castings Quality Assurance to review the requirements, if necessary. The review is intended to develop communication between US Castings Quality Assurance and the Seller.
NOTE MI 14
All items of this Purchase Order are to be 100% Final Inspected or inspected per an approved sampling plan.
BOEING Note:
Operator Self Verification Program: If the Supplier uses an Operator Self-Verification (OSV) program, the Supplier must comply with the requirements set forth in AS/EN/SJAC 9162, “Aerospace Operator Self Verification Programs”, as may be amended from time to time. Buyer reserves the right to conduct surveillance at Supplier facility to determine that Supplier is compliant to the requirements of AS/EN/SJAC 9162.
When Supplier delegates product verification, Supplier must conform to the requirements of AS/EN/SJAC 9117, “Delegated Product Release Verification”.
NOTE MI 15
Seller shall have a process to assure that governmental and safety constraints on restricted, toxic and hazardous substances are complied with relative to purchased products and the manufacturing process.
NOTE MI 16
Materials used must be identified by lot/heat number, material type, specification, and revision and be traceable to records of acceptance.
NOTE MI 17
Buyer and authorized representatives, customer and authorized representatives or regulatory agencies, reserve the right of access to supplier premises at any point of manufacturing to determine quality of work, records and material. This may be done at all reasonable times and may be used to conduct preliminary inspections and tests of the products and work in process. Such investigation by buyer, its customers or regulatory agencies will be performed with the knowledge of and jointly with the supplier.
This right of access shall be flowed down to all levels of the supply chain, including external providers utilized by the supplier to perform work against this purchase order.
NOTE MI 18
Receiving Inspection by US Castings is required.
NOTE MI 19
Equipment shall be labeled with:
- Date of calibration
- Date of next calibration
- Identification of individual performing calibration
- Any limitations
BOEING Note:
The Supplier must retain documented information that provides evidence of monitoring and measurement equipment calibration. The retained documented information must include the required calibration register elements defined within the AQMS standard and the results of calibration.
NOTE MI 20
Calibrations shall be conducted per ANSI/NCSL Z540-1-1994. Certificates and reports of calibration shall comply with ANSI/NCSL Z540-1-1994 sec. 13. Certifications and reports shall also list item calibration due date.
Temperature uniformity surveys, system accuracy tests and pyrometry checks shall conform to the applicable requirements of the latest issues of AMS 2750 and BAC 5621. Reports of testing shall reference the specification the testing conforms to.
Solution heat treat furnaces shall be surveyed at 1000°F +-10°F and precipitation age ovens shall be surveyed at both 310°F +-10°F and 440°F +-10°F.
NOTE MI 21
All items of this Purchase Order are to be inspected by US Castings Quality Dimensional Inspection using Form RI-10 per the requirements of QAP 190.
NOTE MI 22
Any product found to be non-conforming during the performance of work to the requirements of the purchase order shall be positively identified, segregated and controlled to prevent its unintended use or delivery per the requirements of ISO 9001 and AS 9100. The US Castings Purchasing Agent listed on the P.O. is to be contacted to arrange for the product return separate from the accepted work processed.
NOTE MI 23
All calibration and pyrometric service certifications rendered on this purchase order must reference the revision level of the supplier procedure used to perform calibrations as well as any revision levels of industry or regulatory procedures and specifications as applicable.
NOTE MI 24
Suppliers performing work under this order shall implement and control process to ensure the prevention of counterfeit or suspected counterfeit part use including product(s) delivered to US Casting
Supplier, if eligible for utilization of the Government-Industry Data Exchange Program (GIDEP), shall utilize the GIDEP process to screen their material and products for risks, taking appropriate mitigating actions when necessary, and alert the industry of encountered counterfeit parts.
MI Note 25
External provider to provide test specimens per drawing specification for inspection/verification, investigation or auditing.
MI Note 26
Worked performed on this purchase order is being purchased to the conditions of US Castings’ contract with The Boeing Company. Boeing PO Note Q31 is a requirement of this contract and applies to work performed on this purchase order. US Castings’ supplier requirements of Note Q31 are:
“This procurement is under Boeing’s Federal Aviation Administration (FAA) issued Production Certificate 700 quality system supplier control program. Unless explicit contractual direction is given to the contrary, no articles (or constituent parts thereof) ordered by Boeing Commercial Airplanes shall contain any Federal Aviation Administration- Parts Manufacturer Approval (FAA-PMA) markings and the accompanying paperwork (e.g., packages, shippers, etc.) shall not contain any FAA-PMA markings.
Boeing requires that the provisions/requirements set forth above, as determined by the Seller to be applicable, be included in Seller’s direct supply contracts as well as the obligation that they be flowed to the sub-tier supply chain. For purposes of this note, Supply Chain shall mean Seller’s complete network of material, equipment, information, and services integrated into products and services. It focuses on direct and all lower-tier suppliers.”
MI Note 27
Supplier must perform First Article Inspections (FAI) in accordance with AS/EN/SJAC 9102, Aerospace First Article Inspection Requirement. USAC reserves the right to conduct surveillance of the supplier’s FAI.
Supplier shall utilize and document completion of FAI within the Boeing licensed Net-Inspect software. Furthermore, where Supplier is required to document FAIs in the Net-Inspect software, FAIs of the Supplier’s supply chain shall also be document in Net-Inspect
Supplier and Supplier’s supply chain are not permitted to ship product to customer until all applicable FAI requirements have been fulfilled.
8.5.2 Identification and Traceability
a) Supplier must comply with the AS/EN/JISQ 9100 requirements and 14CFR Part 21.2 regarding the application of the Acceptance Authority Media (AAM) requirements.
b) Supplier must, within its organization and its supply chain, ensure that the use of AAM is clearly defined within its Quality Management System (QMS).
c) Supplier must be able to demonstrate evidence of communication to its employees and to its supply chain; use of AAM must be considered as a personal warranty of compliance and conformity.
d) Supplier must maintain compliance to the AAM requirements by assessing its process and supply chain as part of its internal audit activities. The areas of focus for this assessment must include but not limited to:
- Authority Media Application Errors (i.e. Omission, Typos, Legibility, etc.)
- Authority Media Application Untimely Use (i.e. Documentation is not completed as planned, “Stamp/Sign as you go”, etc.
- Authority Media Application Misrepresentation (i.e., uncertified personnel, Falsification of documentation, Work not performed as planned, etc.)
- Authority Media Application Training Deficiencies (i.e. Ethics, Culture awareness, Proper Use of authority media, etc.)
MI28
When Supplier utilizes test reports to accept raw material from External Providers, the following requirements apply:
- Test Reports must be checked 100% against Supplier’s requirements and applicable specifications.
- Validation test requirement: Supplier must periodically validate test reports for raw material accepted on the basis of test reports. That validation must be accomplished by Supplier or other independent party through periodic, scheduled test of raw material samples. Schedules for frequency of tests will be established by Supplier based on historical performance of the raw material provider/manufacturer.
- Supplier must retain test reports provided by the raw material provider/manufacturer, as well as Supplier’s validation test report results as quality records traceable to the conformance of Goods, as specified elsewhere in this Contract.
Supplier must inspect or otherwise confirm that all Products or Services, including the components procured from or furnished by subcontractors or suppliers or USAC, must comply with the requirements of the order prior to shipment to USAC or Customer. Supplier must be responsible for all tests and inspection of the Product during receiving, manufactures and Supplier’s final inspection. Supplier agrees to furnish copies of test and/or control data upon request from USAC Purchasing Representative.
MI29
Supplier is required to establish and maintain a FOD prevention program in compliance with AS/EN/SJAC 9146 Foreign Object Damage (FOD) Prevention Program — Requirements for Aviation, Space, and Defense Organizations
