Ben Walters - Quality Control Documents

Sample Quality Control Documents

Ben Walters Charleston, South Carolina

QUALITY CONTROL DOCUMENTS

Documents containing extensive data (checklists, carbon reflector specifications etc.) were created with Microsoft Excel. Quality Alert and instructional documents containing numerous photographs and annotations were created using Microsoft PowerPoint. Standard Practice documents for use in-house and externally for suppliers / vendors were created with Microsoft Word.

Information contained in the enclosed documents is proprietary and is included to showcase my organizational, design, writing and photography skills. Some changes have been made to the original documents to protect proprietary processes and data. Additional documents are available by request.

AvL Technologies in Asheville, North Carolina is the major manufacturer of satellite antenna positioning units in the United States. Leading clients for the company include; branches of the armed forces, many agencies within Federal & State governments and satellite news gathering organizations such as CNN and ESPN. The following documents are a small representative sample of work I created while I was with the company.

- Ben Walters / Charleston, SC

1. Assembly Instructionsa) Standard Practices Manual – basic across the board procedures

covering everything from metal preparation, to wiring and paintingb) Supplier / Vendor Standard Practices – supplied to vendors to insure

compliance with AVL standards and reduce the amount of rejected material

c) Unit Assembly Instructions – unit family specific instructions covering sub assemblies and final assemblies

2. Unit Checklistsa) Unit Checklists - the cornerstone of quality control for each

manufactured unit3. Quality Alerts & Job Procedures

a) Quality Alerts - when issues cropped up, Quality Alerts were issued to each relevant department detailing concerns and the procedures for rectifying those problems

b) Job Procedures - usually related to manufacturing sub assemblies. Both Quality Alerts and Job Procedures would be incorporated into successive revisions of the Unit Assembly Instructions

Documents created fall under six broad categories;

4. End User Materiala) Quick Start Guides – guides for quickly getting a satellite

antenna positioner up in the field, deploying it and locking onto a satellite signal

b) Case Unit Photographs – laminated photographs showing proper storage of components in their respective cases

c) Field Repair Procedures – generated for specific clients in remote areas to direct the repair of satellite antenna positioner units

5. Data Repositories and Test Resultsa) Reflector Data Master – contained test results for all reflector

dishes generated used a Faro Laser Trackerb) Environmental Test Results – collected data from heat and

load tests of various carbon fiber composites and reflector configurations

6. Miscellaneous Documentsa) Timesheetsb) Parts requisition formsc) Labels and signage

Sample Software Usage InstructionsThese procedures were illustrated using a combination of screen captures and digital photographs (for image quality, where more screen detail was needed). They are used as an adjunct to hands-on training.

Sample Unit Assembly Instructions

Sample Quality Alerts

AvL Technologies Quality Alert

Distribution:Operations Manufacturing Mfg. Engineering Assembly Paint

2.0 Meter reflector’s should be numbered as above (clockwise), as viewed from the back of the reflector. Painted numbers are placed between the center hub and the seams of the reflector petals.

2.0 Meter Sectional Reflector Numbering

QA Number: QA-0049Issue Date: 1/27/06Expires: 2/27/06Issued By: B WALTERS

AvL

12

3

45

6

7

8

AvL Technologies Quality Alert

Distribution: Operations Manufacturing Mfg. Engineering Service Paint

Serial numbers for reflector petals, reflector hub, struts, feedboom, feed horn & unit should be applied in the same place and orientation on all 9066 units, except for the vendor specific labels. Stow & deploy labels should be applied above buttons as shown .

9066 Label Placement

QA Number: QA-0050BIssue Date: 3/15/06Expires: 4/15/06Issued By: B WALTERS

12 point label 12 point label12 point labels

P. 1

12 point label

Standard Serial Number Tagon bottom of unit

GCS only!

Serial numberon front of base

plate

Strut serialnumber facesknurled collar

9 point label

GSI only!

Sample Data Storage Documents

DIE PLUG BALL

241-051-001-B EL D14 - 1.5 - .218 475S1250 1/8 13716 52 13/16 BA 3-4 <20 Ton241-050-001-B AZ D14 - 1.5 - .218 475S1250 1/8 13716 53 13/16 BA 3-4 <20 Ton240-042-001-A EL D14 - .281 478S1500 1/8 13716 74 1/4 BA 3-4 <20 Ton240-041-001-A AZ D14 - 1.5 - .218 475S1250 1/8 13716 101 7/8 BA 3-4 <20 Ton181-232-001 AZ D14 -1.5 - .218 475S1250 3/32 13715 75 1/2 BA 3-3 <20 Ton180-027-003-B AZ D14 -1.5 - .218 475S1250 3/32 13715 60 1/16 BA 3-3 <20 Ton180-027-001 EL D14 -1.5 - .218 475S1250 3/32 13715 54 9/16 BA 3-3 <20 Ton128-037-001-A AZ D14 -1.5 - .218 475S1250 3/32 13715 45 3/8 BA 3-3 <20 Ton128-311-501 D14- .156 A 465S1000 BA 3-2

123-317-301 D14- .156 A 465S1000 BA 3-2

120-072-001 D14- .156 A 465S1000 BA 3-2

075-512-302-A EL (casting) D14- .156 B 465S1000 5/64 13714 38 11/16 N/A N/A075-512-302 EL (old) D14- .156 B 465S1000 5/64 13714 38 3/8 N/A N/A127-032-301 POL D14- .156 B 465S1000 1/16 13712 33 3/4 BA 3-2 <20 Ton120-058-001 AZ D14- .156 A 465S1000 1/16 13712 57 5/8 BA 3-2 <20 Ton120-054-001 EL D14- .156 A 465S1000 1/16 13712 43 7/16 BA 3-2 <20 Ton120-053-001 (270°) AZ D14- .156 A 465S1000 1/16 13712 48 5/8 BA 3-2 <20 Ton120-209-001 POL D14- .156 A 465S1000 1/16 13712 31 7/8 BA 3-2 <20 Ton090-301-001 EL D14- .156 B 465S1000 1/16 13712 36 1/16 N/A N/A077-125-301 POL D14- .156 B 465S1000 1/16 13712 20 9/16 BA 3-2 <20 Ton077-124-301 AZ D14- .156 B 465S1000 1/16 13712 36 BA 3-2 <20 Ton077-123-301 EL D14- .156 B 465S1000 1/16 13712 27 BA 3-2 N/A075-512-303 POL D14- .156 B 465S1000 1/16 13712 24 3/8 N/A N/A075-512-301 AZ D14- .156 B 465S1000 1/16 13712 62 7/8 BA 3-2 <20 Ton075-218-301 EL D14- .156 B 465S1000 1/16 13712 31 15/16 N/A N/A075-217-301 POL D14- .156 B 465S1000 1/16 13712 22 9/16 N/A N/A075-216-301 AZ D14- .156 B 465S1000 1/16 13712 62 31/32 BA 3-2 <20 Ton

<20 TonPlug & Ball Machined

Open hole to .078

Open hole to .078

Cable Drawing Number

CABLE Part

Number

EL 5/64 13714 38 5/8

Hydraulic Force To Swage

Die Number Length (") Ball to Plug Edge

Diameter In Inches

Part NumberCable

Assembly Part Number

<20 TonPlug & Ball Machined

Open hole to .089 (#43) x .46 DP

Open hole to .089 (#43)

AZ 5/64 13714 64 3/4

<20 TonPlug & Ball Machined

Open hole to .089 (#43) x .46 DP

Open hole to .089 (#43)

EL 5/64 13714 38 3/4

Cable Swaging Chart SampleCable Swaging Chart contains parameters for the manufacturing of

stainless steel cables using 20 ton hydraulic press. Used in house for quality control.

Reflector Data Master SampleThe Reflector Data Master contains specific parameters for over 250

carbon fiber reflectors. All data collected and recorded using Faro Laser Tracker.

Unit Checklists are one of the major quality control measures used within thecompany. They accompany each satellite antenna positioning unit during the entire manufacturing process up through crating and shipping. The checklists are used to highlight critical areas of concern and differences between similar units of a particular family. They contain numerous redundancies and secondary checks.

The checklists also reference the actual assembly instruction procedure for each unit sub assembly and final assembly. All documentation including checklists, testing sheets and serial numbers of critical parts were scanned after the unit was shipped, creating a ready electronic reference file. This file aids in field repairs and longevity studies for each positioner unit.

Unit Checklists

Sample Quick Start Guide

The 9066 unit is a suitcase sized solution for a satellite linkup. Many of these units have been sold for use within the government agencies for communications and homeland security purposes. Each unit can replace the approximately 300 phone line connections and can be used logistically for a traveling head of state or in disaster situations

End of document samples

All contents copyright AvL Technologies & Ben Walters

[email protected]