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QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S.p.A.

Contents

1. 86 13 7 RESISTANCE SPOT WELDING STITCH WELDING eere eee nnn nnn 86 138 GENERAL BRAZE WELDING REQUIREMENTS nnne 87 13 9 REQUIREMENTS FOR MECHANICAL UNWELDED CONNECTIONS RIVETS ETC 88 13 10 REQUIREMENTS FOR WELDING ELECTRONIC COMPONENTS SOFT SOLDERING 88 13 11 REQUIREMENTS FOR UNWELDED ELECTRICAL 88 14 AMMUNELON 89 14 1 AMMUNITION AND OR PARTS THEREOF MADE OTO MELARA S SPECIFICATIONS 89 14 1 1 UDO SI it A A A 59 14 1 2 COGI RIO 89 14 1 3 Manufacturing and control process requirements 4 7 885 89 14 1 3 1 Manufacturing and control plan a a ias 89 009200272570 2 sois 90 Ao ot 90 PN LO 90 Dio i ee 90 14 1 3 6 Packing and identification box marking iii 90 14 1 3 7 Despatch to Final CISMA ies 9 14 1 3 8 Test documentation and certification Of the supply iii 9 14 1 4 VOLA 91 14 1 4 1 Quality System PRU a 92 POI iii 92 14143 Documentation for the certification of the SUpply iii 92 OUPRE 92 14 2 STANDARD CATALOGUE AMMUNITION 93 14 2 1 OW S STO eie A ENAS 95 14 2 2 Ammunition destined to OTO MELARA s 222
2. S 67 10 3 1 GDO ipsa 67 10 3 1 1 Risk analysis evaluation dossier RED iii 67 10 3 2 VEZ Manual EAT 67 10 3 3 SCI TOC CSCS pia 67 104 TESNO 67 10 5 ee ee 68 10 6 DECLARATION OF CE CONFORMITY 68 11 PROVISIONS TO ADOPT FOR DEVELOPING THE DESIGN IN COMPLIANCE WITH OTO MELARA REQUIREMENTS 2 2 4 69 11 1 GENERAL C 69 11 2 INSTRUMENTS USED BY OTO MELARA FOR COORDINATION AND SUPERVISION 70 11 3 RAMS RELIABILITY AVAILABILITY MAINTAINABILITY AND SAFETY AND LCC LIFE CYCLE COST REQUIREMENTS Lera 71 114 COMPONENTS WITH SAFETY CRITICALITY LEVEL 1 eere rene 71 11 5 DESIGN PART LIST IBASELINE cuestionan pt s 72 TL SERIES PRODUCTION cuesta 72 dbs QO e 72 12 SE VV PUES A o UA 73 12 1 SOFTWARE REQUIREMENTS 73 12 2 SOFTWARE IMPLEMENTATION 73 12 3 SOFTWARE MODULE FUNCTION TESTS 73 124 SOFTWARE INTEGRATION 73 12 5 SOFTWARE INTEGRATION TESTS AND
3. 104 18 1 ATTACHMENT 1 VERIFICATION AT SUPPLIER s RECORDING FORM EXAMPLE 104 18 2 ATTACHMENT 2 JOB ORDER DOCUMENTATION MANAGEMENT AND CHANGE INTRODUCTION RECORD EXAMPLE 105 18 3 ATTACHMENT 3 MANUFACTURING AND CONTROL 106 18 3 1 DINE VD OU OIC ie iii 106 18 3 2 10140570 E 107 18 4 ATTACHMENT 4 CERTIFICATE OF CONFORMITY FORM ee eene 108 18 4 1 LODO E SE 108 18 4 2 109 18 5 ATTACHMENT 5 WELDING PROCEDURE SPECIFICATION FORM 110 TABLES TABLE 1 DOCUMENTATION ISSUED BY rita Ie iaia 15 TABLE 2 DOCUMENTS ISSUED BY THE 2 22 22000000 00 02002 0 0000 0000000 16 TABLE 3 DOCUMENTS ISSUED BY THE SUPPLIER THAT IMPACTS ON DESIGN DEPT CONTINUES FROM iiiv 17 TABLE 4 1 ISSUED BY THE SUPPLIER THAT IMPACTS LOGISTICS DEPT CONTINUES FROM TABLES A 18 TABLE S CRITICALITY LEVEE m a M 20 TABLE 6 COMMODITY CLASSIFICATION ui 20 TABLE 7 CORRESPONDENCE BETWEEN THE SUPPLY CRITICALITY LEVEL AND THE SUPPLIER QUALITY MANAGEMENT SYSTEM LEEVEBL cele 24 TABLE 8 INSTRUCTIONS FOR AC
4. 97 16 1 GENERAL tods 97 16 2 SUPPLIER S ORGANISATION AND 97 16 3 DEVELOPMENT OF THE ASSIGNED 97 16 4 MELARA S CONTROL ON THE SUPPLY iii 97 17 ACTIVITIES DEVELOPED BY SUPPLIERS AT COMMISSIONING AND SERVICE GENTRES ipod 99 17 1 GENERAL 99 17 2 DOCUMENTS SUPPLIED BY OTO 99 17 3 DOCUMENTS DRAWN UP OR PRODUCED BY THE SUPPLIER 100 17 4 ORGANISATION OF THE SUPPLIER S PERSONNEL AND RESOURCES 100 17 5 SUBCONTRACTED MATERIALS AND SPARE 101 17 0 SENINSTOWORK 101 WARRANTY SERVICE curtir 101 17 8 MANAGEMENT OF NON CONFORMITIES AND 101 17 9 INTRODUCTION OF MODIFICATIONS AND FIELD INTERVENTIONS 102 17 10 CONTROL EFFECTED BY MELARA ON THE 103 17 11 OPERATING INSTRUMENTS sicarios 103 18 1 1 2 1 6
5. AQAP 2130 NATO QA Requirements for inspection and testing if only production is envisaged AQAP 2131 NATO QA Requirements for final inspection if only production is envisaged AQAP 2210 Additional NATO QA requirements for Software ISO 9001 2008 EN AS JISQ 9100 2009 AER Q for Aeronautical products AQAP AQAP 2110 NATO QA Requirements for design development production if design and development is envisaged AQAP 2120 NATO QA Requirements for production if only production is envisaged AQAP 2130 NATO QA Requirements for inspection and testing if only production is envisaged AQAP 2131 NATO QA Requirements for final inspection if only production is envisaged AQAP 2210 Additional NATO QA requirements for Software ISO 9001 2008 EN AS JISQ 9100 2009 AER Q for Aeronautical products AQAP AQAP 2110 NATO QA Requirements for design development production if design and development is envisaged AQAP 2120 NATO QA Requirements for production if only production is envisaged AQAP 2130 NATO QA Requirements for inspection and testing if only production is envisaged AQAP 2131 NATO QA Requirements for final inspection if only production is envisaged Manual and procedures adequate to activities as proven by vendor List Certification by a recognised third party ISO 9001 2008 EN AS JISQ 9100 2009 or second party AQAP AER Q AQAP requirements will
6. 04 A Finmeccanica Company August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A 18 ATTACHMENTS 18 1 ATTACHMENT 1 VERIFICATION AT SUPPLIER s RECORDING FORM example OTO MELARA MODULO REGISTRAZIONE VERIFICHE FORNITORI Attivit svolta da NOMINATIVO MATRICOLA CENTRO D ATAJE USCITA E CODICE FORNITORE lora LOCALITA PROVINCIA TOTALE PERSONALE OTO MELARA SpA IMPEGNATO NELLA VERIFICA COLLAUDO INTERMEDIO COLLAUDO FINALE AUDIT DI SISTEMA AUDIT DI PRODOTTO ESITO TOTALEORE ATTIVITA PIANIFICATA ES SU PFC PROGRAMMA VERIFICHE ISPETTIVE _ ATTIVITA NON PROGRAMMATA _ necessaria la seguente causale Barrare la tipologia della verifica ESITO Indicare la percentuale di CONFORMITA riscontrata nel corso delle attivit Es 0 10 20 100 95 ORE Indicare il numero di ore totali impiegate per la verifica DA COMPILARE A SEGUITO DELLE ATTIVIT DI COLLAUDO Numero Ordine Posizione Numero Disegno Costruzione Quantit Quantit Quantit Ordine presentata Accettata Non Conforme Motivo della e Non Conformit Note Firma del Fornitore Firma del Personale OTO Melara SpA Firma dell eventuale Rappresentante del Cliente DISTRIBUZIONE AGQ SQ sempre allegandolo al foglio di viaggio Nel caso di collaudi L3 Fornitore da allegare alla distinta di
7. Eg a Y Y A YY 41 loro Note In the case of Aeronautical products the ISO 9001 Quality System Level is replaced with EN AS JISQ 9100 AQAP Quality System Level is replaced with the corresponding AER Q QP Quality Plan always includes the MCP 28 MCP Manufacturing and Control Plan COC Certificate of Conformity FAI First Article Inspection to be repeated in the event of important manufacturing process or Suppliers change it is mandatory for supplies of aeronautical products S TT Type Tests charged to the Supplier when applied to products designed by it 32 WPS Welding Procedure Specification SPC Applied Special Process certificate HTC Heat Treatment Certificate can consist of certificate relevant to the obtained mechanical characteristics such as hardness resilience tensile strength furnace according to characteristics criticality level STC Surface Treatment Certificate NDT Non Destructive Tests Acceptance Test Procedure and relevant Test Report 35 PQR Procedure Qualification Record BT Ballistic Test when required 7 DCC Dimensional Characteristics Certificate QSL Quality System Level When assemblies are designed by the Supplier see also Table 9 ii Includes also intermediate manufacturing operation 4 RQA0001 MELARA QUALITY REQUIREMENTS 31 of 110 04 A Finmeccanica Company August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p
8. MELARA QUALITY REQUIREMENTS 27 A Finmeccanica Company August 2012 referenced standard WPAR or PQR reference number date of issue approvals w Specific indications Welding process Type of process TIG MIG MAG with electric resistance RSW Covered Electrode and method manual semiautomatic automatic robot welding for the welding used Joint drawing Graphic representation of the welded joint with an indication of the related dimensions and methods for preparing the relative edges Joint Indication of the type of joint welding material the proprieties must be the same as the base material or reaction plate ceramic or different material incoherent preparation and cleaning prior to the welding of both edges specifying whether brushes or solvents must be used depending on the type of material treated for aluminium alloys is suggested a stainless steel brush Base material Indication of the group number the type and grade of the material treated steel aluminium etc the thickness and outside diameter of the edges filler material Indication of the normative references UNI ISO for Europe and AWS for the USA and the proprieties of the material such as the classification dimensions trade name manufacturer and welding device Welding position Indication of the positions horizontal vertical L shaped etc welding direction ascending or descending and any other useful indications Pre
9. This documentation must include at least the following information a type of alloy and flux used b methods and times for cleaning the welds procedures for cleaning painting the printed circuit boards where applicable d type of solvent and paint when applicable for the operations of the previous point All this must comply with the provisions set out under the manufacturing procedures OTO PF 030 01 PF 030 02 PF 050 nn PF 020 01 for the assembly of components Moreover when welding components that are sensitive to electrostatic discharge the Supplier must provide locations suitable for this type of activity that are in compliance with the provisions set out in OTO MELARA s procedure PF 040 22 13 11 REQUIREMENTS FOR UNWELDED ELECTRICAL CONNECTIONS For the purpose of obtaining the required authorisation before starting series production the Supplier shall provide OTO MELARA Quality with the documentation required to carry out the set welding process this document must be drawn up in compliance with OTO MELARA s manufacturing procedures OTO PF 040 nn and OTO PF 070 nn Code 0001 89 of 110 7 OTO MELARA QUALITY REQUIREMENTS e A Finmeccanica Company Date August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A 14 AMMUNITION w 14 1 AMMUNITION AND OR PARTS THEREOF MADE TO OTO MELARA S SPECIFICATIONS The aim of this subsection is to define the quality requirements to
10. De gt E d lt O 18 3 2 Form example OLSIATHA OGNVNO ALNATIO 22 VAVIHHOLO THOLINHO V LITVAO NENNEN INOIZVAO3NddV IMOLINHOJ VILITYN AHO LIN HO TAI ALAVd OLNANWIHHAIH VG 38V VT TAG Id OTIOULNOD _SOINFAUAINI IO HINA ANOIZVISALIV OTIOMINOD OINAWAJOA 2 34 5NOIZVODHSSIV 07 ALON ONDASIA L VUNLINYO OLLOGOUd OTIOULNOD ANOIZVORIAAVA ONVId RQA0001 108 of 110 7 MELARA QUALITY REQUIREMENTS A Finmeccanica Company August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A 18 4 ATTACHMENT 4 CERTIFICATE OF CONFORMITY FORM 18 4 1 Drawing up Guidance AAA ee ee AA AAA AAA AAA A ee ae AAA AAA AA PP mmm mmm mmm mmm uc Reference on Explication the form 4 Purchaser Name in this case OTO MELARA SpA 20 OTO MELARA order n and relevant variantsifany 3 Government Contract reference only when is mentioned in OTO 00 0 00000 000000000000 4 of the Certificate of Conformity addressee for example OTO 2 site of La Spezia or site of Brescia 1 5 Supplier that issues the Certificate of conformity data and production facility address 6a of the addressee of the material only if different from the PERENNEM Certificate of Conformity addressee 1 6b Reference of Transport Document with the warning to ind
11. T3 12 0 SOFIWARERELEAS E 74 12 7 MAINTENANCE DURING PRODUCTION STAGE AND AFTER 74 RQAO0001 a o 7 of 110 7 MELARA QUALITY REQUIREMENTS a A Finmeccanica Company August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A 12 8 SGOPIZWAREOWNERSIIP ansiado 74 12 8 1 Software developed by the Supplier iii 74 12 8 2 Commercial Software COTS or Modified 8 1 020 4000 000000500000 nnne nes 74 12 9 APPLICABLE REQUIREMENTS insano 75 12 10 WORK PRODUC Saito int 75 12 10 1 LR 75 12 10 2 Description of the main Work Products and their use in system software development 76 13 GENERAL REQUIREMENTS FOR WELDED JOINTS AND UNWELDED MECHANICAL ELECTRICAL 82 13 1 GENERAL REQUIREMENTS FOR MECHANICAL WELDS 82 13 1 1 General requirements for control activities esee eene nnn nn nennen nenne sensns nnns 83 132 WELDING PROCEDURE SPECIFICATION 5 4 2 4 0 4 4 121 83 13 3 WELDING PROCEDURE QUALIFICATION WPAR PQR 1 eere nennen 84 134 CONTENTS OF THE WPARIPQN xii 85 13 5 SPECIAL RULES FOR BALISTIC 5 2 212 1 85 13 6 GENERAL RULES FOR STAINLESS STEEL WELDED JOINTS
12. Technical Quality For action For examination and Questionnaire to be updated to be handled together Supplier List update every two years or after each with Quality Assurance significant change to the organisation 2 Balance of last two years for For competence Suppliers with supply value towards OTO MELARA exceeding 200K Quality Manual to be For info through Supplier For info through Supplier For action constantly updated List List e Supplier List update 4 Request for authorization for For competence Sub Suppliers with attached list of main sub Suppliers to be delivered during the negotiation Order confirmation original 5555 6 Quality Plan Configuration For verification and approval within 15 working days of receipt Management Plan within 60 calendar days of receipt of the order 7 Manufacture Control plan to through for For verification and be delivered together with obtaining approval for those parts Quality Plan approval of of competence prior to technological commencement of content activities 8 Special and critical processes specifications employed as an alternative to those envisaged For info For verification and in OTO MELARA technical approval prior to documentation to be delivered commencement of within 30 calendar days from activities the order receipt 9 Welding Process Specs WPS and mechanical For verification and electrical joints process specs approval prior to to be
13. as well as evidence of audits conducted successfully at the Suppliers premises by OTO MELARA Quality personnel This is also desirable with level 2 items in which case certification issued by OTO MELARA Quality can be considered sufficient OTO MELARA s Supplier List will contain a list of Suppliers with specific competences features and proof of qualification which must be kept up to date by the Suppliers also filling in the dedicated questionnaire sent by OTO MELARA Procurement Department 5 3 1 Sub Suppliers Quality System level Suppliers with orders of items classified as 1 or 2 in case of use of sub Suppliers shall ascertain their appropriate certification consistently with what is reported in par 5 3 above Allied Quality Assurance Publication RQAO0001 QUALITY REQUIREMENTS si of 110 August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A O0T0 MELARA A Finmeccanica Company TABLE7 CORRESPONDENCE BETWEEN THE SUPPLY CRITICALITY LEVEL AND THE SUPPLIER QUALITY MANAGEMENT SYSTEMLEVEL Criticality Supplier Quality Management System with certification 7 7 e level covering activities requested by OTO MELARA ISO 9001 2008 EN AS JISQ 9100 2009 AER Q for Aeronautical products AQAP AQAP 2110 NATO QA Requirements for design development production if design and development is envisaged AQAP 2120 NATO QA Requirements for production if only production is envisaged
14. interface matrix OTO MELARA and Supplier Added Paragraph 3 1 Suppliers classification Paragraph 7 of previous rev has become par 6 Added paragraph 5 2 identification of critical characteristics on drawings Updated Table 7 correspondence between the supply criticality level and he Supplier Quality management Quality Level tables 8 17 associating Quality Management System ISO 9001 AQAP for each commodity class Added commodity class V mechanical catalogue parts and W Military catalogue products developed by Suppliers Updated par 7 1 2 traceability par 7 3 Special processes 7 6 FAI 7 7 3 Government Surveillance 8 6 Manufacturing and Control Plan 8 7 documentation relevant to components with criticality level 1 8 9 Safety data sheets 8 10 Certificate of Conformity par 10 equipment fixtures designed by Suppliers cap 13 general requirements for welded joints cap 14 Ammunition Updated in the whole document ISO 9001 2000 to ISO 9001 2008 04 Review in accordance with the requirements of EN AS SJAC 9100 2009 Quality modified chap 3 reference standards chap 4 interfaces chap 5 identification of requirements of OTO Melara and correlation with supplier s quality system chap 6 synoptic tables chap 7 definitions and general requirements chap 8 management of contract documentation chap 9 packaging and chap 10 equipment designed by the s
15. possible repaired or reworked promptly by the Supplier at its expense as soon as possible Finally rejected products have not be resubmitted to OTO MELARA The results of Inward Quality inspections contribute to the Vendor Rating w 7 7 6 Recording of activities on the documents The Suppliers and Sub Suppliers are responsible for the performance and recording of all the tests and inspections defined in the documents requested by OTO MELARA The document on which the tests and inspections are recorded must contain at least the following elements of definition a Identification of the product subject to inspections and tests and its configuration p n and s n where required the types of tests inspections conducted a reference to the test method or the document followed for the activities the test results the instruments used where applicable the date of execution the signature of the authorised persons The defect repair or elimination data and the non conformity reports must be recorded and remain at the Supplier s for consultation by OTO MELARA and or the Customer Q 0200c 7 8 TYPE TESTS The Type Tests of validation characterise the item or device in a set environment or specific environments such as the climate heat thermal shock cold ice sand wind rain relative humidity etc the marine environment waves external pressure etc the electromagnetic field EMI EMC lightning etc the vibrating
16. rods extruded items castings or forgings The required protection can be obtained with the transport container 9 4 3 Mechanical standardised parts screws nuts washers etc Multiple packaging in an individual clear polyethylene bag thickness 2 0 2 mm weighting maximum 3 Kg i RQA0001 64 of 110 MELARA QUALITY REQUIREMENTS des A Finmeccanica Company August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A 9 4 4 Hydraulic pneumatic materials a All the openings in the hydraulic components motors pumps valves drawers rigid hose pipes fittings etc must be protected with plastic plugs of a suitable size alternative solutions are not allowed b rigid hose pipes can be packed directly in on the transport container with a package that differs for each type of pipe individual packing is also required in the case of painted rigid pipes c the hose pipes can be rolled up provided that the bending ray is not less than the minimum ray specified in the catalogue d the packing of rubber pipes must be provided with an identification card showing the pipe polymerisation vulcanisation date as well as the date of assembly of the fittings to the pipe materials with a limited life e on rubber pipes even if in absence of packing the identification number shall be applied w 9 4 5 Electric Electronic Materials a For electric electronic normalised items multiple packaging is allowed prov
17. 1 which also show the departments issuing and receiving them Below are details of the Procurement Departments of the two production sites OTO MELARA S p A OTO Unit Procurement Department Via Valdilocchi 15 19136 La Spezia ITALY Tel 39 0187 582209 OTO MELARA S p A BMB Unit Procurement Department Via Lunga 2 25126 Brescia ITALY Tel 39 030 3791212 The various types of documents must be physically identified and separated so that there is no doubt as to which department they must be forwarded Delays in the internal distribution of documents attributable to the Supplier due to wrong type identification may generate non conformity reports preventing payment of the invoices and penalising the Supplier s rating The Supplier must also refrain from consigning the supply when it is not accompanied by the necessary documentation because a the product will be declared nonconforming b its ranking will be lowered due to the non conformity attributable to it The dates of consignment of documents refer to the letter of intent the contract and or the purchase order Applications for deviation or waiver from the requirements set out in this document which must always be approved by OTO MELARA Quality Department should be addressed to the Procurement Department A RQA0001 15 of 110 04 A Finmecca ica Company August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A 4 1 INTERFACE MATRIX
18. 1 Identification By identification is meant a system which with suitable means markings punching plates tags transport documents allows identification of the type and denomination of the various products throughout the production process Identification is assured by correlation between the physical products and the identification data shown on the markings The Supplier is responsible for providing identification means for supplied product 7 1 2 Traceability By traceability is meant a system that allows each product or batch of products to be recognised and distinguished from other identical ones but made separately and under different conditions and at different times and to be correlated with the documentation recording the processes inspections and tests undergone by the system The Supplier agrees to maintain throughout the production cycle adequate identification of the materials components and anything else received for subcontracted work and to ensure proper correspondence as explained in the preceding paragraph 7 1 2 1 Minimum Requirements The system shall identify at least part origin manufacturing date lot and evidence of acceptance 7 1 2 2 Identification Methods For those items for which it is required the identification number shall be univocal When traceability is required items and material lots shall contain an univocal identification such as serial number lot number and date codes Methods and marking posi
19. 7 OTO MELAR A A Finmeccanica Company Date August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A Two examples of designation are reported as follows a for OTO MELARA La Spezia plant b for OTO MELARA BMB Unit Brescia a an item obtained by machining safety criticality level 2 commodity class for quality C mechanical component is designed as in figure for what relates to legend additional legend dedicated to safety and quality classification part list and order Be 2 2 5 E T D c or 8 33 E ego yo 5 5 59 z OS uo Oz a a il Il T D LI z 4 O 9 o n DRAWING NUMBER Uu E o E T P N De 1 i Oo 991163108103 01 xx XXX Legend Order Incase of old drawings can be present in an associated list Figure 1 Example of designation OTO MELARA La Spezia plant RQA0001 22 of 110 OTO MELARA QUALITY REQUIREMENTS d A Finmeccanica Company August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A b an item obtained through investment casting commodity classification G safety criticality level 1 is designed as in figure for what relates to legend additional legend dedicated to safety and quality classification part list and order 7 9 E 5 S 9 Uu P m 9 gu tai o c m Po 25 o E KM 58408 25 5 ES 25 mz E OS wo 5 5 ce i ui E E zu 6 S 3 S n DR
20. BETWEEN THE LEVEL OF THE SUPPLY CRITICALITY LEVEL OF CERTIFICATION OF THE PROCESS OF WELDING OR RESPECT OF RELATIVE REQUIREMENT Criticality Quality Requirement of Reference Level the welding process Standards Comprehensive quality ISO 3834 2 Certification by a recognized third party agency requirements or as an alternative an adequate quality system assessed and certified by OTO MELARA through dedicated inspections and audits w Comprehensive quality ISO 3834 2 3 Certification by a recognized third party agency requirements Standard or as an alternative an adequate quality system mE quality requirements 25 m assessed and certified by OTO MELARA through dedicated inspections and audits Standard quality ISO 3834 3 4 The Supplier shall must develop document requirements Elementary implement a system that gives a good level of quality requirements iai confidence that items are consistent with the requirements gt According to what established by OTO MELARA welding coordinators 1 According to what is established by MELARA welding coordinators RQA0001 83 of 110 oTo MELARA QUALITY REQUIREMENTS a A Finmeccanica Company August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A Harmonised standards referenced by EN ISO 3834 don t exclude validity of qualification achieved in accordance to AWS MIL ASME standards provided they are compatible with the specified act
21. DEVELOPED BY SUPPLIERS AT COMMISSIONING AND SERVICE CENTRES i g Refer to subsection APPLICABILITY above for instructions on how to handle these activities 17 1 GENERAL The section refers to Suppliers who are required to execute the following activities at service centres e commissioning of mounts launchers or apparatuses status verification execution of corrective maintenance introduction to the agreed modifications or shortfalls compilation of failure reports and work sheets and on site activity management management of non conformities and direct contact with OTO MELARA representatives for their solution e reporting of significant malfunctions and problems The Supplier draws up and makes available to OTO MELARA the service Quality Plan which is subdivided into the following sections e organisation of on site structure with the name of the personnel employed method of execution of the activities assigned spare parts warehousing method relations with OTO MELARA and the end Customer operating instruments used In case activities are coordinate by OTO MELARA s personnel present at the yard or job sites the Quality Plan is not requested 17 2 DOCUMENTS SUPPLIED BY OTO MELARA The Supplier operating at the job sites normally receives the following documents and is responsible for using them correctly and maintaining them up to date e test plan and test procedures for commissioning communication of any modifications made
22. JOINT GIUNTI Joint Type Tipo di Giunto Backing Sostegno Weld preparation Preparazione PARENT MATERIAL MATERIALE BASE Group No Gruppo to al Group No Gruppo Spec Type amp Grade to con Specif Tipo e Grado Thickness Spessore WELDING CONSUMABLE MATERIALE D APPORTO Specification No Norma No AWS Designation Classificazione AWS Size Dimensioni Manufacturer Costruttore WELDING POSITION POSIZIONE DI SALDATURA Position Posizione Welding Progression Progressione di saldatura PREHEAT PRERISCALDO Preheat Temp Temperatura di preriscaldo C Interpass Temp Temperatura di interpasso C GAS ES GAS Percent Composition Composizione 6 Gas es Mixture Flow Rate Gas Miscela Portata Shielding Protezione Trailing Aggiuntivo TECHNIQUE TECNICA String or Weave Beads Cordoni stretti o larghi Multiple or Single Pass Passata singola o multipla per lato Heat imput Apporto termico Filler metal Electrode size Materiale apportol Dimensioni Type amp Polarity Amperes mm Tipo e Polarit A Welding Process Processo di saldatura Current Corrente Layer s Tensione Velocit Saldatura MANUFACTURER COSTRUTTORE APPROVAL APPROVAZIONE
23. MELARA The drawings the Quality Plans the Manufacturing and Control plans the Technical opecifications and any other documentation sent by the Supplier must be at least in the Italian language and in any other language specified on the Order Printed documents must be delivered in reproducible form and that can be scanned If the required documentation is not delivered payment of the related invoices may be withheld Delivery of documents may be binding for payment of invoices relevant to various deliveries If any of the test documents certificates type weight chemical and physical properties visual inspections and dimensional checks are not presented OTO MELARA reserves the exclusive right to decide whether to perform the tests itself or have them done by an independent body and the Supplier will be charged the costs sustained and damages for the delay For all painted components for which OTO MELARA does not provide painting specifications regardless of the criticality level the Supplier must present the painting process in advance including the technical specifications of the products and the thickness of the coats applied together with the Manufacturing and Control Plan if there is one or the Conformity Certificate The documentation covering a Qualification of the welders b Qualification of the welding procedures c Qualification of the operators for Non Destructive Test d Qualification of Special processes m
24. MELARA and the Customer The Supplier or its authorised Sub Suppliers must acknowledge that OTO MELARA and the Customer in general the Italian Ministry of Defence or those of foreign countries or the Italian MoD representing that of foreign countries with mutual government assistance have the right to conduct inspections at their production facilities provided that reasonable notice is given Furthermore at the Supplier s document approval stage MCP OTO MELARA and the Customer have declared their intention to attend certain tests or manufacturing activities the Supplier must summon in writing e g fax Quality Control manager of the OTO MELARA production site involved with at least 10 working days notice The written call sent by the Supplier must contain the following details e areference to OTO MELARA contract order e the test item and a description of the test e reference to the documents MCP with phases indication a that require the binding presence of OTO MELARA Quality and possibly the Customer for the continuation of the activities point H b which must be notified by a certain notice given to OTO MELARA Quality and eventually to the customer so that they may at their discretion be present point W c in which it is required to issue a test report point R e the quantity to be tested the place of execution of the test the date of the test and its expected duration e the Supplier s contact for reference purposes e
25. OTO MELARA AND SUPPLIER TABLE 1 DOCUMENTATION ISSUED BY OTO MELARA ISSUING Technical For info For competence documentation specified on the order and not attached to it 3 Test procedures For info For info Through specified on the order and not attached to it 4 reference For info For competence For info configuration production phase 5 Changes to orders For action For info For info For info purchase ISSUING documents 6 Non conformity Through For info For action Monitoring by For info when debit reports ISSUING Vendor Rating note is envisaged Report of tests c o For info For info For action For info For info for negative the Supplier ISSUING Monitoring by results in case of Vendor rating debit note Debit notes For action For info For info For action FORMALIZATION ISSUING Monitoring by Vendor rating 10 Shipment documents For action For info for example through General sub contracted Warehouse material STQ Technical Services of Quality only at La Spezia plant 2 QPM Quality Program Manager Issues and signs the cover letter RQA0001 16 of 110 04 A Finmeccanica Company August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A TABLE 2 DOCUMENTS ISSUED BY THE SUPPLIER Documents issued by the OTO MELARA departments involved in document despatch Supplier Procurement Materials Quality Material Quality Assurance Management Incoming Inspection STQ IQPM
26. Q A set of programs rules procedures documentation and data relating to the operations of digital calculator based system 5 4 16 Ammunition R Parts of subassemblies forming the projectile shell the fuse any driving parts energy generating components batteries cartridge cases sabot links explosive charges propellants primers artifices complete ammunition containers and carrying boxes RQA0001 27 of 110 oTo MELARA QUALITY REQUIREMENTS 2 A Finmeccanica Company August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A 5 4 17 Hydraulic or pneumatic components S Parts or subassemblies for the generation and or distribution of fluid energy pumps pressure relief valves sequence valves pressure reduction valves electric or mechanical directional valves servo valves proportional valves bladder and piston accumulators cylinders servo cylinders motors angular motors etc 5 4 18 Activities performed by Suppliers at the OTO MELARA plant internal T A series of activities assigned to Suppliers who as well developing the product at their own facilities assembly it on the system on the OTO MELARA production lines w 5 4 19 Services rendered by Suppliers at the Customer s facility external A series of activities assigned to Suppliers having the organisational structure means and skills to develop technical activities installation and logistics at the End Customer s 5 4 20 Catalo
27. The absence of the certification any mismatching of the certifying document with the product values that are incomplete or differing from the expected ones cause the issue of Non Conformity Reports and thus the suspension of the payment of the invoices i RQA0001 66 of 110 7 MELARA QUALITY REQUIREMENTS 97 August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A 10 EQUIPMENT DESIGNED BY THE SUPPLIER This chapter supplements the requirements set out previously For further details reference must be made to subsection APPLICABILITY The term equipment means any item necessary to support the manufacturing control logistic support process The present document cannot be alternative to the consultation and knowledge of European Community Directives that must be followed during the practical operations Note If the design activity is developed by the Supplier under OTOMELARA responsibility based on a Requirement specification definition the design process to be followed is defined in Table 9 while the documentation to be issued has to be supplemented with that required by the applicable European Directives Table 15 and will be verified approved by OTOMELARA w 10 1 SAFETY RULES Design manufacturing and testing of an equipment or a fixture hereinafter briefly named equipment shall conform to European Directives in case of CE marking or in case the r
28. and Development activities the Supplier shall apply also the requirements of the specific product in accordance with Table 9 6 Shelf life The materials subject to wear must have at the time of receiving in OTO MELARA a residual life not less than 75 of the useful life specified by the manufacturer unless otherwise specified by OTO MELARA in the documentation accompanying the purchase order 4 RQA0001 MELARA QUALITY REQUIREMENTS E 04 A Finmeccanica Company August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A TABLE 8 INSTRUCTIONS FOR ACTIVITIES AND DOCUMENTS ACCORDING TO THE CLASSIFICATION 11 12 13 14 15 16 17 18 19 20 21 22 Non metallic indefinite materials CG AAA Functionally important non metallic Em AQAP 2120 HA AQAP 2130 AQAP 2130 structures and mechanical components IC AA ER A AA A IPM Note In the case of Aeronautical products the ISO 9001 Quality System Level is replaced with EN AS JISQ 9100 AQAP Quality System Level is replaced with the corresponding AER Q QP Quality Plan always includes the MCP MCP Manufacturing and Control Plan 9 COC Certificate of Conformity 14 FAI First Article Inspection to be repeated in the event of important manufacturing process or Suppliers change it is mandatory for supplies of aeronautical products 2 Tests WPS Welding Procedure Specification
29. and integrations thus reducing non conformity or delay risks the documents relevant to this phase are for instance e Quality Plan PQ Configuration Management Plan CMP e Manufacturing and Control Plan MCP e Acceptance Test Procedure ATP e Welding Procedure Specification WPS These documents require OTO MELARA approval b In the act of delivering manufactured items with the aim of having required quality evidences for instance Certificate of Conformity and certifications Test report of functional dimensional performance checks and various certifications such as certificates stating the conformity of the characteristics of the materials used NOTES 1 The Supplier making reference to the synoptic tables relevant to the applicable Commodity Class shall carry out activities and supply documents and evidences as requested 2 In case OTO MELARASs technical data package does not define the criticality level the Supplier shall apply what reported for items of safety criticality level 2 except for the case where it s evident the need to refer to safety criticality level 1 3 In those cases when Commodity Class of the item to be supplied is not referable to the synoptic tables paragraphs 1 9 apply 4 Synoptic tables do not report documentation required by law described for some cases at paragraphs 8 8 8 9 non metallic materials technical sheets and safety data sheets for chemicals 5 When the supply consists of design
30. any d verification of the qualification of special and critical processes welding gluing crimping painting heat treatments surface treatments and the personnel involved e verification of NDT personnel qualifications verification of the quality of the raw materials certifications of the chemical and physical properties verification of the validity of the production equipment for the first product inspection of the manufacturing and control support documentation verification of application of the Manufacturing and Control Plan MCP verification that the requirements of the key characteristics are satisfied verification of component trace ability verification of the trace ability of certifications and NDTs dimensional checks and visual inspections function tests and related procedures aesthetic finish weighting inspection of the packaging and preparation for despatch w h ovocopg s zso 7 7 INSPECTIONS AND TESTS 7 7 1 Inspections and tests conducted by the Supplier Inspections and tests shall be carried out according to standards and rules related to personnel safety The Supplier must perform and is responsible for all the tests and inspections specified in the contract documents and those ones developed by the Supplier MCP and previously approved by OTO MELARA sending to OTO MELARA the relevant certifications and test reports This is required regardless of whether OTO MELARA s or the Customer s personn
31. available to operators in the relevant work place Unless otherwise specified on the drawing and or order OTO MELARA special process specifications must be applied Examples of identification codes by process are OTO RS surface treatments OTO TT heat treatments OTO PS surface polishing OTO VE painting OTO GO rubber parts PF manufacturing processes etc If the Supplier intends to adopt its own specifications they must be submitted for approval to OTO MELARA Quality Materials Incoming Inspection and or Product Quality within 30 days of receipt of the order and anyway before commencement of activities For welding please refer to the subsection entitled GENERAL REQUIREMENTS FOR WELDED JOINTS AND UNWELDED MECHANICAL ELECTRICAL CONNECTIONS When the supply involves painting not dependant on OTO MELARA specifications the oupplier must attach to the MCP if there is one details of the painting cycle as well as product data sheets and the thickness of the films applied If there is no MCP the Supplier must send this documentation to OTO MELARA before consignment of the first lot of the supply 7 3 3 Welding For welding make reference to the dedicated paragraph GENERAL REQUIREMENTS FOR WELDED JOINTS AND UNWELDED MECHANICAL ELECTRICAL CONNECTIONS 7 3 4 Painting When supply includes painting not bound to OTO MELARA specifications the Supplier shall attach to the MCP when required the painting procedure inclusive of
32. be applicable in accordance with AQAP 2009 Annex C and to what reported in detailed prescription for each commodity class Certification by a recognised third party ISO 9001 2008 EN AS JISQ 9100 2009 or second party AQAP AER Q Alternatively Suitable system structure proved and certified by visits and audits by OTO MELARA personnel AQAP requirements will be applicable in accordance with AQAP 2009 Annex C and to what reported in detailed prescription for each commodity class The Supplier must develop document implement maintain a system that gives a high level of confidence that the items or services meet the requirements AQAP requirements will be applicable in accordance with AQAP 2009 Annex C and to what reported in detailed prescription for each commodity class 1 In case the order or the contract or the specification cited don t define the safety criticality level the Supplier shall apply what reported for items of safety criticality level 2 except for the case where it s evident the need to refer to safety criticality level 1 RQA0001 25 of 110 oTo MELARA QUALITY REQUIREMENTS a A Finmeccanica Company August 2012 2 If the Supplier has ISO certification only it must integrate the Quality Plan with the NATO AQAP requirements listed in the NATO Specific Requirements of the AQAP applicable to the type of goods supplied For aeronautical products if the supply is subject
33. before the approval of the FAI by OTO MELARA The approval of the FAI results provides evidence that the production process the production documentation and the equipment are suitable for producing parts and assemblies that meet the requirements The FAI must be repeated and must be presented in a formal way to OTO MELARA if changes occur that invalidate the original results already approved in the previous FAI for example engineering changes changes to the manufacturing process modifications to the equipment changes of production facilities site changes of suppliers In the event that the repetition of the FAI covers only parts of the product process it is called partial repetition of the FAI In any case the FAI will have to be repeated in full after an interruption of production of two years unless this deadline is not otherwise specified in the Purchase Order i RQA0001 42 of 110 7 MELARA QUALITY REQUIREMENTS di A Finmeccanica Company August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A 7 6 1 FAI execution method The inspection takes place in the following stages a verification of the identification of the product undergoing the FAI and its marking by OTO MELARA personnel when required b verification of compliance with the applicable configuration verifying the correspondence with the last revision of the drawings lists and applicable specification c review of any non compliance recorded if
34. by the Quality function or the Head of the company drawn up in accordance with the form referred to in Annexe B of AQAP 2070 b copy of the certificates of conformity of any lot batched components c copy of the required test recording forms d identification codes of the products materials included in the supply containing dangerous substances under the REACH Regulation and the related safety data sheets These test and conformity certificates together with the Quality Plan and the Manufacturing Control Plan shall be filed and kept by OTO MELARA Quality 14 1 4 Simple products Under ammunition by simple products are meant all those not included in the list of complex critical products e g spacers or cardboard parts loose metal parts RQA0001 92 of 110 7oTO MELARA QUALITY REQUIREMENTS A Finmeccanica Company August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A For the simple products the Supplier shall comply not only with all the points specified above see subsection APPLICABILITY but also with those below g 14 1 4 1 Quality System Organisation For the type of activity required by the product to be supplied the Suppliers Quality oystem shall comply at least with the AQAP 2131 or ISO 9001 2008 standards 14 1 4 2 Production and testing The activities required to fulfil the requirements specified in the OTO MELARA s order shall be planned over a manufacturing control cycle The Supp
35. compliance of the supply OTO MELARA reserves the right to approve the final test procedure and attend the final tests 14 2 3 1 Final tests The tests must be performed in accordance with the procedures approved by OTO MELARA by defining the sampling plan OTO MELARA Quality must attend the final tests when firing a complete round A conformity audit will also be performed to check compliance with the test requirements specified in the documents generated by the Supplier and any Sub Suppliers 14 2 3 2 Test attendance The Supplier must send OTO MELARA Quality with a prior notice of at least 10 working days an invitation to attend the test of the object covered by the contract During these tests OTO MELARA Quality reserves the faculty to choose the samples to test 14 2 3 3 Product handling The products must be handled in compliance with the contract requirements and the applicable provisions of law in order to protect the product and the personnel involved right from when the material enters the factory throughout all the manufacturing control stages up until final delivery RQA0001 95 of 110 oTo MELARA QUALITY REQUIREMENTS a A Finmeccanica Company August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A 14 2 3 4 Packing and identification box marking The products must be packed in compliance with the requirements set out in the technical documentation and the provisions of law Compliance of Packing and ident
36. functional drawings and charts required to introduce modifications use and maintenance handbooks and spare parts catalogues missing parts list spare parts list job order development schedule for Supplier s activities forms on which to record the activities carried out oingle Document on the Assessment of Risk from Interference DUVRI as applicable The Supplier is responsible for promptly reporting any inconsistencies or incompleteness in the above documents RQA0001 100 of 110 oTo MELARA QUALITY REQUIREMENTS a A Finmeccanica Company August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A 17 3 DOCUMENTS DRAWN UP OR PRODUCED BY THE SUPPLIER In case of activities of which the Supplier has complete responsibility it shall follow what is reported below The Quality Plan is the document used by the Supplier to officially state compliance with the provisions specified in subsection 16 1 The plan must be presented to OTO MELARA within 60 calendar days of the date on which the Supplier has received the assignment letter or purchase order The Plan must be submitted by the Supplier for a review should any of the following occur modifications to the dedicated structure e organizational changes remarks by MELARA following assessment For commissioning the Supplier must make available 30 days prior to the start of the tests a general execution programme in the form of a GANTT chart showing e the test sequen
37. load c degree of design maturity derivation or otherwise of the item assembly from systems similar assemblies validated at the prototype stage or ones which have provided good proof of function resistance and are therefore able to undergo comparative engineering analysis covering the requisites d degree of technological constructional verification and or testing difficulties The criticality levels are defined in decreasing order in Table 5 i RQA0001 20 of 110 MELARA QUALITY REQUIREMENTS d A Finmeccanica Company August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A NUMERIC CODE CRITICALITY LEVEL 1 CRITICAL CLASS Parts assemblies operations and actions associated directly and indirectly with the safety of persons and the system weapon parts directly subject to the firing gas pressure or associated with the projectile loading function or cartridge case ejection and in general highlighted by a Safety Analysis conducted according to the criteria prescribed in the applicable standards CRITICALITY LEVEL 2 IMPORTANT CLASS Parts assemblies or operations associated directly and indirectly with the mission functionality or burdensome replacement in terms of time and cost CRITICALITY LEVEL 3 COMMON CLASS In the absence of the conditions described for the two previous levels In case the order or the contract or the specification cited don t define the safety criticality level the Supplier shal
38. products technical sheets and indication of film thickness In case the MCP is not required the Supplier shall send the above documentation prior to first lot delivery for OTO MELARA Quality approval 7 3 5 Heat Treatments When supply consists of Heat Treatments execution on blanks or parts machined at OTO MELARA or at OTO MELARA s Suppliers facilities what reported at paragraphs 7 3 1 e 7 3 2 relevant to qualification level or procedure specification applies RQA0001 40 of 110 oTo MELARA QUALITY REQUIREMENTS T A Finmeccanica Company August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A The Supplier shall produce the evidences related to the executed treatments by issuing the appropriate certificates When heat treatment is part of castings or moulded parts supply the relevant evidences shall be delivered included in the required documentation When mechanical characteristics are determined by initial treatment such as austenitizing quench and temper the exact treatment temperature i e tempering temperature shall be recorded and made available in the delivery documentation to permit the accurate determination of possible further treatments i e stress relieving without altering the mechanical properties Temperature vs time diagram of the treatments that determines mechanical properties gives the required information The Supplier shall be in condition to show evidence that treatment equipment is under c
39. progressive components aggregation test plan 7 RE 1 Software Validation Verification of requirement Y achievement the Report shall trace all requirements at various level OR 1 System test Test strategy WP 14 applied to the N strategy entire system PR 1 System test plan Test plan WP14a applied to the Y entire system OR 1 Regression test Test strategy WP 14 applied to N strategy check whether a change to the software affects the system performance PR 1 Regression test Test plan WP 14a to check whether plan a change to the software affects the Y system performance OR 1 Acceptance test Test strategy WP 14 applied to the Y strategy entire system for validation by the Customer PR 1 Acceptance test Test plan WP14a applied to the plan entire system for validation by the Y Customer N RQA0001 79 of 110 Tera ana QUALITY REQUIREMENTS 2 1 August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A Test procedure Operative description of test plan general actuation General this applies to each test level Test report general Results of the execution of a test procedure General this applies to each test level Configuration This defines the rules to maintain Management the uniformity between the strategy plan CM components of the system software versions following carefully and recording all contro
40. reviewed in order to ensure that the defect found may not be repeated upon receipt of a Report of Non Conformity Repair Order it must acknowledge receipt confirming that as containment measures all stocks have been checked and cleared from the defect recorded where a failure survey report is required the report must be submitted within 30 working days or within 10 days if it concerns safety from the receipt of the rejected Product the report must contain in detail the containment action necessary to prevent that potentially defective products belonging to the same batch or manufactured with the same tools and methods are used extending to check out any inventory stored in OTO MELARA or at the Supplier in order to exclude the possibility that they are affected by the same defect The corrective action to prevent the repetition of the product failure 7 11 4 Testing For each reworked repaired product the Supplier must perform the scheduled tests according to the procedures provided or drawn up by OTO MELARA and approved by OTO MELARA Quality Objective evidence of these activities must be presented OTO MELARA Quality and the Customer if necessary has the right to attend the tests The presentation to the tests must be effected as described on the initial order pertaining to the consignment 7 11 5 Documentation required The materials supplied must be accompanied by the following documentation a Ascertainment repo
41. that must record the despatch together with all the test results The Supplier can despatch the material in compliance with the order requirements only after having received formal authorisation from OTO MELARA The Supplier is responsible for getting the couriers to comply with all the rules and regulations regarding ammunition as prescribed by the applicable law or the technical documentation supplied by OTO MELARA Quality 14 1 3 8 Test documentation and certification of the supply 1 depending on the type of product the Supplier must make available to OTO MELARA Quality and supply on request the following documents a the workshop test recording forms for lot batched and or serial components including those supplied by Sub Suppliers b the firing test recording forms for lot batched and or serial components e g propellant igniters cartridge cases explosive discharged projectile charged projectile c the fuse SAU factory test recording forms d the fuse SAU firing test recording forms e the complete cartridge factory test recording forms f the complete cartridge firing test recording forms This documentation must be filed together with that covering the supply and kept by the Supplier according to the provisions set out in subsection 14 1 3 1 2 At the end of the acceptance test of the object covered by the order the following documents must be sent to OTO MELARA a Certificate of Conformity of the supply signed
42. the List for qualitative and or performance problems e Suppliers that are considered suitable to provide products or services to OTO MELARA but do not have orders in progress and to which it is not planned to issue orders in a short term are considered potential Suppliers are also classified according to commodity class classes they are able to supply Suppliers are subject to a Rating according to specific algorithms detailed information related to the Vendor Rating are available in Quality Suppliers Profile of internet site http www otomelara it Suppliers Quality management System is subject to OTO MELARA surveillance and approval Inspections and audits including sub Suppliers can be carried out before during of after a purchase order is given w The supplier will be informed of the deficiencies that may have been found during these inspections or audits to which they are required to provide a prompt solution The corrective actions must be submitted to examination and approval by OTO MELARA Quality Department see also paragraph SUPPLIER QUALITY SYSTEM LEVEL i RQA0001 14 of 110 MELARA QUALITY REQUIREMENTS 2 11 August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A w 4 MELARA INTERFACES All the documents required for the supply issued by OTO MELARA and to be provided by the Supplier are shown in the tables in subsection 4
43. the Order The product serial number and or the lot number must also be specified Manufacturing may not commence until the Manufacturing Control Plan and the Quality Plan and the Configuration Management Plan when required has been approved If these plans have been sent by the Supplier but not yet formally approved by OTO MELARA Quality the Supplier must formally ask OTO MELARA Quality for the authorization to proceed 8 1 SECURITY OBLIGATIONS CONFIDENTIALITY The Supplier must take all the necessary precautions to prevent divulgation and improper use of documentation belonging to OTO MELARA All the documents used must be considered confidential unless otherwise classified OTO MELARA s property rights must be protected 8 2 DOSSIER OF THE CONTRACT REQUIREMENTS AND RELEVANT CONFIGURATION MANAGEMENT When the negotiations have been completed and the order confirmation issued the Supplier must prepare and keep a dossier containing the following documents a the order b the order confirmation c any changes to the order d the specific technical documentation referred to in the order drawings specifications standards and or references to the documentation classified and kept according to the applicable rules e a list of the applicable documents with their revisions and proof of controlled distribution within the Suppliers own organisation and at the Sub Suppliers see for example attachment 2 f a copy of the latest revision
44. will be conducted between the Supplier and OTO MELARA Quality to analyze the non conformities recorded on the products involved in order to find out corrective actions with effective improvements 7 10 MANAGEMENT OF NON CONFORMITIES FOUND BY OTO MELARA IN THE PRODUCTS SUPPLIED Non conformities found by OTO MELARA a atthe Supplier s in the course of tests inspections or audits b atthe Sub Suppliers involved by the Supplier in making the product at OTO MELARASs facilities during receipt of the goods or installation d at other OTO MELARA Suppliers to whom the Supplier has sent the product according to OTO MELARA instructions e atthe Customer s for reasons due to the Supplier will be classified by OTO MELARA in the NCRs and communicated to the Supplier according to the following criteria NON CONFORMITIES CLASSIFIED AS REJECT OTO MELARA will return the product to the Supplier or prevent the delivery to its facilities NON CONFORMITY CLASSIFIED AS USE AS IS OTO MELARA will manage the relevant activities related to deviation waiver requests In both cases OTO MELARA s Administration Finance and Control department upon the receipt of communication by the Procurement department will charge the Supplier for the expenses held for issuing and managing the Non Conformity including hours materials and other technical costs The charged hours are determined on a objective basis and with a formal procedure NON CONFORMITIES
45. 200000005000 eene ssnn nnne s nnns 95 14 2 2 1 Manufacturing and control plan iii 95 14 2 2 2 Testattendance iii 93 I MEME A 95 14 2 2 4 EA 95 14 2 2 5 Packing and identification box marking iii 95 14 2 2 6 Despatch to Final Customer eese eene 94 14 2 2 7 Test documentation and certification Of the supply iii 94 14 2 3 Ammunition destined to OTO MELARA tests eene eene eene nn non nan nennen eene sensns nnns 94 PIO 94 Mii OS CNC OIEA AP REE E OOO oasis sa Sake 94 WEDS FI 94 14 2 3 4 Packing and identification box marking iii 95 14 2 3 5 Despatch to the site specified by OTO MELARA i 95 14 2 3 6 Test documentation and certification of the 2 000000000000000 0 0 eene eene 95 15 USER MANUALS AND SPARE PARTS CATALOGUES 96 15 1 GENERAL 96 RQAO0001 a o 8 of 110 OTO MELARA QUALITY REQUIREMENTS 25 August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A 15 2 DOCUMENT DEVELOPMENT 00 044 10000 96 153 PENALTIES 96 16 ACTIVITIES DEVELOPED BY SUPPLIERS OTO MELARA
46. 2210 applies Type Tests TS Technical Specification exhaustively describing all performances operational and storage environmental conditions SVDD Software Version Description Document i RQAO0001 y QUALITY REQUIREMENTS 5 of 110 A Finmeccanica Company August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A 7 OTO MELARA Table 12 INSTRUCTIONS FOR SCREWS NUTS AND BOLTS 2 RESISTANCE CLASS gt 8 8 Y yf Vv v In accordance with indications SO 9001 AND DIA 2 8MM contained in order drawings or in 4Q4P 2131 their absence UNI o ISO standards a 9001 identification on ISO 9001 wire electrode AQAP 2130 container TABLE 14 REQUIREMENTS FOR SUPPLIER DEVELOPED MILITARY PRODUCTS AVAILABLE IN A CATALOGUE ow pyrr ut AQAP 2210 Note In the case of Aeronautical products the ISO 9001 Quality System Level is replaced with EN AS JISQ 9100 AQAP Quality System Level is replaced with the corresponding AER Q 100 Casting Chemical Analysis certificate Hc Hardness Certificate U WDCC Visual Dimensional inspection Certificate 1 COC Certificate of Conformity QSL Quality System Level to be applied 15 MPC Mechanical Properties Certificate TS Technical Specification inclusive of interface specification and installation drawings 107 y Validation certificate of design and development 8 ATP Acceptance Test Procedure and relevant Test Report 1916 Documentation f
47. 7 15 1 Spare parts for technical support to validation 51 7 15 2 Spare parts included in the supply and or in stock ii 52 8 MANAGEMENT OF CONTRACT DOCUMENTATION AND DOCUMENTATION REQUIRED BY OTO MELARA caracas nadadora 53 8 1 SECURITY OBLIGATIONS 22 0 0 22 22 54 8 2 DOSSIER OF THE CONTRACT REQUIREMENTS AND RELEVANT CONFIGURATION MANAGEMENT osas 54 8 3 REQUESTS FOR MODIFICATION TO TECHNICAL DESIGN DOCUMENTATION 54 8 3 1 Products made by the Supplier based on technical documentation supplied by OTO MELARA 54 6 3 2 Products designed by the Supplier to OTO MELARA specifications ii 55 8 4 SUE PP PP 55 RQAO0001 a o 6 of 110 MELARA QUALITY REQUIREMENTS o A Finmeccanica Company August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A 8 5 CONFIGURATION MANAGEMENT PLAN iii 56 8 6 MANUFACTURING AND CONTROL 2 444 2 2 2 2 1 56 8 6 1 Visual Dimensional inspection 57 8 6 2 Typical Manufacturing and Control 58 8 6 3 CIO ORRORE OOC IRA 58 8 7 DOCUMENTATION RELEVANT TO ITEM WITH CRITICALITY LEVEL 1 58 8 8 TECHNICAL CHARTS FOR NON METALLIC MATERIALS AND CHEMICALS 58 8 9 SAFETY D
48. A TABLE 8 CONTINUED CLASS FAI CAC TSC MA HID BT REFERENCE QSL 41 42 43 44 45 46 dr 49 50 STANDARDS 51 Metallic indefinite materials and unfinished products EE EEE indications contained AQAP 2130 in order drawings or in their absence UNI o ISO standards ISO 9001 AQAP 2130 5 ISO 9001 2130 with Mum 9001 7 he 52 indications contained 2130 in order drawings or in their absence UNI o Bd AM ME ISO standards Forged and moulded accordance indications contained AQAP 2130 in order drawings or in their absence UNI o ISO standards AQAP 2130 A 55 Note In the case of Aeronautical products the ISO 9001 Quality System Level is replaced with EN AS JISQ 9100 AQAP Quality System Level is replaced with the corresponding AER Q MCP Manufacturing and Control Plan FAI First Article Inspection to be repeated in the event of important manufacturing process or Suppliers change it is mandatory for supplies of aeronautical products S sa Casting Chemical Analysis certificate TSC Tensile Strength certificate ITC Impact test Certificate COC Certificate of Conformity Metallographic Analysis HTD Heat Treatment Diagram HC Hardness Certificate BT Ballistic test when required gt QSL Quality System Level 52 CoC Certificate of Conformity supported by Inspecti
49. A S p A 7 1 1 OLO A Te 37 TAZ TT 37 4 1 2 1 VEE IIIT A ei 27 Feb 42 OTO NINA TS 37 7 1 2 3 DIO 37 7 1 2 4 T LAN TTT e AAEE N T 37 7 1 2 5 ACC 38 7 2 STORAGE APP 38 7 3 SPECIAL AND OR CRITICAL 38 Lou POS ti 39 72 39 7 3 3 A A 39 7 3 4 Ix n M 39 7 3 5 zT NRI MPE 39 7 4 TEST AND PROCESSING INSTRUMENTS EQUIPMENT iii 40 7 5 NON DESTRUCTIVE TESTS ND risesscecconsitccccaracsecuscstocccssicscazectssncesestssdescacticesoubiccastnaceeuencetiencen 40 7 6 EXECUTION OF THE FAI FIRST ARTICLE 41 7 6 1 PACCO E aos 42 7 7 INSPECTIONS AND TESTS cisne 42 du sd Inspections and tests conducted by the Supplier iii 42 Inspections and tests at the Supplier s or its Sub Suppliers supervision by MELARA and the CUSTOM ato rotas 43 7 7 3 Government SUVE aaa 43 7 7 4 Work Progress MONITO III 44 259 Acceptance inspections and tests at OTO MELARA facilities ii 44 7 7 5 1 VOLO III 44 A URB II c E 44 2 MIlano 45 PR
50. ATA CHARTS as 59 8 10 CERTIFICATION OF CONFORMITY TO OTO MELARA PURCHASE ORDER 60 8 11 FILING AND CONTROL OF THE DOCUMENTS RECORDING THE SUPPLIER S ACTIVITIES 61 9 PACKING AND 2 1 12 2 62 9 1 dg eic Bag d 62 9 2 LOGISTIC PACKING REQUIREMENTS 62 9 3 GENERAL REQUIREMENTS cccsscsssccssecsnsecsussecessensessnsacsussecesecassecsesensessnsacsussecussensesaneassussess 62 9 3 1 Individual PACA 62 9 3 2 OOO ORE 62 9 3 3 A 3 9 4 SPECIAL REQUIREMENTS ctra 63 9 4 1 Small size parts to ITONTAS ii 63 9 4 2 117 65 9 4 5 Mechanical standardised parts screws nuts washers etc M iii 65 9 4 4 Hydraulic pneumatic materialS iii 64 9 4 5 Elec Electronic MIGICTIONS siii 64 9 4 6 CHIC 64 9 4 7 CATA ARR e O E 64 9 4 8 Ferrous end products without any protective surface treatment isses 65 9 4 9 Material despatched directly to an other Supplier of OTO MELARA cesses 65 10 EQUIPMENT DESIGNED BY THE SUPPLIER 66 10 1 SAFETY i lcm 66 102 CEMARKING C ee 66 UNE ILIIIC Mr
51. AWING NUMBER i5 o E T PIN E Di d m 5 O o o A1140 558415100001 01 XXX Order Incase of old drawings can be present in an associated list Figure 2 Example of designation OTO MELARA Brescia plant N B The commodity group has significance for OTO MELARA internal processes only and is not disclosed to Suppliers RQA0001 23 of 110 oTo MELARA QUALITY REQUIREMENTS 2 August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A 5 2 CRITICAL CHARACTERISTICS IDENTIFICATION ON DRAWINGS In drawings critical characteristics for item classified as 1 or 2 critical levels are identified by a symbol triangle shaped A which contains the number corresponding to the assigned criticality class Supplier shall give to OTO MELARA evidence of records of those characteristics for each item together with the other ones listed in the control sheet w 5 3 SUPPLIER QUALITY SYSTEM LEVEL As a basis the Supplier Quality System shall conform to ISO 9001 EN AS JISQ 9100 for Aeronautical products In general once established the Supplier s production capability related to the commodity class before it can receive orders relating to criticality level 1 items it must have a Quality Management System certified by a recognised body ISO AQAP AER Q with a field of application consistent with the activities to be performed for OTO MELARA
52. BCONTRACTED MATERIALS AND SPARE PARTS Materials subcontracted by OTO MELARA for modification or integration or identified as spare parts must be preserved in such a way as to maintain their identification Withdrawal order and make sure they do not get damaged The Supplier must report immediately e quantity shortfalls compared to the accompanying documents and damage to the materials or components received any non conformities found during installation or testing 17 6 SETTING TO WORK Setting to work activities is carried out by OTO MELARA s personnel who is responsible for that in case the Supplier carries out these activities autonomously it shall fill the documentation provided by OTO MELARA Setting to work takes place on completion of installation lt involves a series of tests inspections and controls and ends with provisional delivery of the product to the Customer provided that the following tests have been passed e Static tests e dynamic tests 17 7 WARRANTY SERVICE Service activities are normally under the responsibility of OTO MELARA personnel in case the Supplier carries out these activities autonomously it shall fill the documentation provided by OTO MELARA The service activities under warranty that the Supplier must perform between delivery of the product and expiry of the warranty for each product include e Interventions of repair after failures corrective maintenance e the introduction of modifications and o
53. CLASSIFIED AS REPAIR or REWORK If a non conformity is found at Supplier s it will be recorded and managed on site together with the Supplier according to applicable procedure in case of deviation waiver RQA0001 48 of 110 oTo MELARA QUALITY REQUIREMENTS a A Finmeccanica Company August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A If a non conformity is found during Inward quality inspection OTO MELARA will contact the Supplier to agree on the action the Supplier will take at the OTO MELARA facilities using the product If the Supplier fails to take action within the agreed time OTO MELARA qwill initiate the restore repair procedure OTO MELARA s Administration Finance and Control department on the basis of Procurement Department communication shall charge the Supplier the costs of the hours spent and the materials used to perform the repair or reworking activities and of the subsequent inspections OTO MELARA s standard hourly charge for the current year will be applied w If the Supplier intervenes at the OTO MELARA facilities it may in agreement with Operating Department in compliance with production planning and with reference to the quantity of non conforming products agree whether to 1 repair or rework the product with its personnel at the OTO MELARA facilities or at its own premises 2 leave OTO MELARA repair or rework the product in which case the Supplier will pay all the costs involve
54. Code RQAO0001 QUALITY REQUIREMENTS e a 110 Date August 2012 mma Finmeccanica Company QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A THIS DOCUMENT CONTAINS ALL THE QUALITY REQUIREMENTS APPLICABLE TO OUTSOURCED SUPPLIES NOTICE A printed copy of this document may not be in the revision currently in effect the current version is always in Quality section of OTO MELARA web site www otomelara it or for OTO MELARA employees in intranet site The user of this document Supplier or OTO MELARA employee who considers that some aspects require clarification can send his comments to www otomelara it Quality FAQ contacts Apart for what relates to general aspects the document can be consulted by focusing on the specific supply commodity class Security Classification Issued by Authorised by Exists LI Does not exist X Dr S Lucchinelli Dr R Cortesi OTO MELARA S p A OTO MELARA S p A Quality amp ICT GENERAL MANAGER OTO MELARA S p A a Finmeccanica Company copyright all rights reserved Code RQA0001 OTO MELARA QUALITY REQUIREMENTS Page 20f110 Rev 04 A Finmeccanica Company Date August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A PROCESSING DRAWN UP BY CHECKED BY Dr E Stretti Quality System OTO MELARA S p A Quality amp ICT Quality System Manager APPROVALS Organization and Human Resources Ms G Zullo Development _ _ SVP
55. FOR SUPPLIES TO OTO MELARA S p A 1 DOCUMENT SCOPE AND OTO MELARA PROCUREMENT POLICY This document covers minimum general Quality Assurance requirements for supplies to OTO MELARA S p A referred to hereinafter as OTO MELARA It is OTO MELARA policy to supply superior quality products and services that meet the Customers requirements and come up to their expectations OTO MELARA believes that Suppliers are key elements in its processes with whom to share responsibility for Customer satisfaction w This document summarises all the Quality Requirements applicable to supplies to OTO MELARA This document is an operative tool for use in the procurement process for company departments to help them issue purchase orders and check the results and for the Supplier who will find in it the information needed to develop the supply correctly In particular OTO MELARA incoming inspection will make reference to tables reported at paragraph 6 to evaluate supplies conformity Concerning the Design the document provides guidance on the technical documentation required in order to facilitate the compilation and subsequent evaluation review If OTO MELARA or the Design Authority of the product licensed to OTO MELARA has produced specific documents covering the supply they will take priority over the general requirements contained herein Any departure from these requirements will constitute a non conformity unless specifically app
56. IE AO RR III TETTI 45 Acceptance AICTUM 45 7 7 6 Recording of activities on the documents iii 46 7 8 TIPE TESSA os 46 7 9 MANAGEMENT NON CONFORMITIES FOUND BY THE SUPPLIER 46 7 10 MANAGEMENT OF NON CONFORMITIES FOUND BY OTO MELARA IN THE PRODUCTS SUPPLIED 47 7 11 REWORK OR REPAIR ACTIVITIES RELATED TO NON CONFORMING PRODUCTS FOUND AT OTO MELARA s OR AT CUSTOMERSYS 4 44444 48 7 11 1 RICO A at 48 7 11 2 Ascertainment Record for materials belonging to the Customer under repair or servicing 46 7 11 3 Rework 22222000000000000015 000 46 7 11 4 MO P 49 7 11 5 Documentation VCQUITCE T 49 7 11 6 Notification of non compliance related to products delivered Quality Alert sss 50 7 12 LIABILITY FOR SUB SUPPLIERS MANAGEMENT eere eene nennen nnn nnn nnn nn nnn nn 50 7 13 LIABILITY FOR SUBCONTRACTED WORK MATERIAL BELONGING TO OTO MELARA OR THE END CUSTOMER jcc c 50 7 14 ACCESS TO THE PREMISES AND DOCUMENTATION OF OTO MELARA S SUPPLIERS AND SUBSUPPEIERS Rella 51 TIS S V a Oe eee eee 51
57. It is necessary to use safe storage places for the documentation to prevent deterioration and ensure traceability such as for example fire resistant drawers duplicate copies kept in other places All data stored by electronic means must be stored on reliable and safe support regularly duplicated and checked for integrity Suppliers equipped with a computer system for documentation storage must have a procedure to recover the data ready for application in the event of disasters this must be defined documented implemented and regularly inspected for compliance In case of insolvency of the Supplier he she is required to deliver all relevant records to OTO MELARA RQA0001 y 62 of 110 7 OTO MELARA QUALITY REQUIREMENTS a A Finmeccanica Company August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A 9 PACKING AND SHIPMENT w 9 1 APPLICABILITY The provisions covered by this subsection are applicable unless otherwise indicated in the order to all outsourced raw materials semi finished products and end products made to drawing and purchased from the trade hereinafter simply referred to as materials used for production and as spare parts The following provisions indicate the minimum requirements for packaging the supplies and if the packaging would be incomplete or insufficient it is the Supplier s job to adopt the most appropriate solutions to avoid inconveniences in order to prevent the risk of deteri
58. L LEVEL ITEMS SERIES ITEMS SERIES INCOMING LOT SAMPLE CRITICALITY LEVEL CRITICALITY CRITICALITY LEVEL 1 LEVEL 2 3 Ac Re Ac Re 20 2 0 1 1 2 1 2 11 30 6 71 2 2 3 3 4 5 6 Key to symbols Ac Acceptance threshold maximum number of acceptable minor non conforming items per series for each incoming lot If the threshold is exceeded OTO MELARA will switch to reinforced sampling charging the Supplier with the relevant cost Re Rejection threshold maximum number of minor non conforming items series leading to rejection of the entire lot If non conforming units are found in the course of the sample checks but the products are required urgently for use or assembly or to avoid production stoppages OTO MELARA may after having informed the Supplier decide not to reject the lot or batch and make a selection to use the conforming products materials if any see paragraph 5 13 the cost will be charged to the Supplier This solution does not however relieve the Supplier from its liability in connection with completion of the non conformity remedy procedure 12 As per MIL STD 1916 RQA0001 46 of 110 MELARA QUALITY REQUIREMENTS a A Finmeccanica Company August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A OTO MELARA is entitled to reject non conforming products or to ask for them to be repaired or reworked Non conforming products will be removed and where
59. LARA Quality to request during the supply the attendance at any intermediate final tests of the components During these tests OTO MELARA Quality reserves the faculty to choose what components ammunition are to be tested as samples 14 2 2 3 Final tests OTO MELARA Quality shall attend the final tests when firing a complete round A conformity audit will also be carried out to check compliance with the test requirements specified in the documents generated by the Supplier and any Sub Suppliers 14 2 2 4 Handling The products must be handled in compliance with the contract requirements and the applicable provisions of law in order to protect the product and the personnel involved right from when the material enters the factory throughout all the manufacturing control stages up until final delivery 14 2 2 5 Packing and identification box marking The products must be packed in compliance with the requirements set out in the technical documentation and the provisions of law Compliance of Packing and identification must be verified by the Suppliers Quality function that must record the results of this check together with all the test results RQA0001 94 of 110 oTo MELARA QUALITY REQUIREMENTS 2 A Finmeccanica Company August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A 14 2 2 6 Despatch to Final Customer The material must be despatched after successful completion of the checks on the packaging marking and identi
60. LT delivery time SMR CODE code relevant to procurement type substitution levels and repair of the spare Economic quotation of the spare Indication of useful tooling for maintenance and relevant logistic information Economic quotation of tooling mentioned in previous point 3 spare parts relevant to assemblies subassemblies designed by the Supplier OTO MELARA Part Number if assigned Manufacturer Part Number Closest assembly NHA FSCM spare manufacturer NATO code Description spare identifying title Code of the spare referred to type and use System criticality code related to failure of the item considered Repair code if can be repaired or not Quantity for nearest assembly opare total quantity in the system Reliability datum MTBF i RQA0001 53 of 110 7 MELARA QUALITY REQUIREMENTS ay Finmeccanica Company August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A Expected life for wearable parts Shelf life Lot minimum deliverable quantity Dimensions length width height Weight PLT delivery time SMR CODE code relevant to procurement type substitution levels and repair of the spare Economic quotation of the spare Indication of useful tooling for maintenance and relevant logistic information Economic quotation of tooling mentioned in previous point w 8 MANAGEMENT OF CONTRACT DOCUMENTATION AND DOCUMENTATION REQUIRED BY OTO
61. MECHANICAL ELECTRICAL CONNECTIONS 13 1 GENERAL REQUIREMENTS FOR MECHANICAL WELDS In general unless otherwise specified in OTO MELARA s orders or in the referenced technical documentation welding activities shall be performed in accordance with quality requirements of standards of the family ex UNI EN 729 729 2 729 3 29 4 replaced by UNI EN ISO 3834 3834 2 3834 3 3834 4 one to integrate the Supplier s Quality System already fulfilling the ISO 9001 2008 standards for welded constructions That family of standards is structured in a way to be used as reference for any weld construction conforming to different quality levels addressing adequately all welding processes and all related aspects capable to influence the finite product quality In particular the following elements are considered project and or contract review identification of the critical characteristics Identification of the risks and their management with the implementation of the actions required to mitigate the risks management of residual risks sub Supplier welding personnel inspection and test personnel equipment welding activities filler metal base material storage after weld heat treatments Inspections and tests in accordance with appropriate UNI EN standards if not otherwise specified conformity and corrective activity calibration identification and trace ability documentation TABLE 17 CORRESPONDENCE
62. OTO MELARA S p A 14 2 STANDARD CATALOGUE AMMUNITION i g In this case the Supplier must prove under its responsibility the validation of the Supplied Product Refer to subsection APPLICABILITY above for instructions on how to handle the supply of standard ammunition There are two types of standard catalogue ammunition a Ammunition destined to OTO MELARA s Customers as a supplement to its own supplies b Ammunition destined for OTO MELARA tests 14 2 1 Quality system For the envisaged activities the Supplier Quality System shall comply with AQAP 2110 2210 and ISO 9001 2008 14 2 2 Ammunition destined to OTO MELARA s Customers In this case OTO MELARA must monitor the quality of the supplied products The requirements specified for the ammunition and or parts thereof produced according to the technical documentation supplied by OTO MELARA shall apply except for the fact that all the activities are performed under the Supplier s primary responsibility and OTO MELARA itself monitors the manufacturing control process 14 2 2 1 Manufacturing and control plan The provisions under subsection MANUFACTURING AND CONTROL PLAN MCP shall apply in addition to what specified in the previous subsection 14 1 3 1 a b 14 2 2 2 Test attendance The Supplier must send OTO MELARA Quality with a prior notice of at least 10 working days an invitation to attend the test of the object covered by the contract It will be up to OTO ME
63. Quality amp ICT Dr S Lucchinelli VISA QUALITY DEPARTMENTS m RESPONSIBILE E Quality La Spezia plant Dr A Pigoni Quality Brescia plant a i Dr S Lucchinelli FOR CONFORMITY TO ORIGINAL SA Date cole 2 0 Dr S Lucchinelli OTO MELARA S p A SVP Quality amp ICT Code 0001 Page 3of 110 MELARA QUALITY REQUIREMENTS E A Finmeccanica Company Date August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A w REVISION INDEX Modifications made Department bend into English of RQA0001 rev 01 issued in June 2005 02 October 2007 Introduced par 1 1 guide to the consultation of document RQA0001 Modified Business Logo Cap 3 Reference standards Cap 7 Table 8 specification of the typology of the documentation of control according to UNI EN 10204 adding class F par 5 1 1 criticality level par 5 3 1 non metallic indefinite materials Cap 12 additions prescription on the relative norms to requirement of quality for the welding and modified the standard of reference from UNI EN 729 to UNI EN ISO 3834 03 February 2010 Added cover note related to document file availability on company web site and to collection of comments and request for clarifications Added note at paragraph 2 Applicability for what relates to OM facilities production processes Updated Paragraph Reference standards Updated Paragraph 4
64. RA S p A procedures are valid for other metals which reference standard is described in the family of UNI EN ISO 15614 i e 15614 1 Qualification procedures are described in UNI EN ISO 15614 cited in UNI EN ISO 3834 for the specific activities Welding test specimens relevant controls and tests to be executed are specifically described in the family of UNI EN ISO 15614 standards applicable these activities shall be executed in presence of the examiner EWF professional or of the examiner body third party legally recognised i e Bureau Veritas RINA Istituto Italiano Saldatura and so on For qualifying a welding procedure its necessary to draw a preliminary WPS pWPS according to the appropriate UNI EN ISO 15614 family of standards and to the applicable part of EN ISO 15609 in which validity and welding parameters shall be specified and all information regarding the execution of the weld test specimen shall be described The pWPS shall make reference to other support standards EN or ISO such as EN ISO 4063 for numerical coding of welding process while for base materials the reference is given by CEN ISO TR 15608 For filler metals the reference to be used have been issued by Under committee SC3 Welding consumables If test specimens result compliant the WPAR PQR is obtained it shall show in details the achieved results and shall be undersigned by the examiner or the examiner body To make an easy evaluation of data a specifi
65. SPC Applied Special Process Certificate HTC Heat Treatment Certificate can consist of certificate relevant to the obtained mechanical characteristics such as hardness resilience tensile strength furnace according to characteristics criticality level STC Surface Treatment Certificate NDT Non Destructive Tests 8 Acceptance Test Procedure and relevant Test Report bi 2 PQR Procedure Qualification Record for welding Ballistic Test when required DCC Dimensional Characteristics Certificate 22 QSL Quality System Level 23 COC Certificate of Conformity supported by Inspection Certificate type 3 1 according to UNI EN 10204 that it is considered also applicable to non metallic Certificate of Conformity COC Certificate of Conformity supported by Inspection Certificate type 3 1 according to UNI EN 10204 COC Certificate of Conformity as an alternative for parts not based on OTO Melara requirements Declaration of Conformity on type 2 1 according to UNI EN 10204 When applicable 4 RQA0001 0T0 MELARA QUALITY REQUIREMENTS 04 A Finmeccanica Company August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A TABLE 8 CONTINUED 27 28 29 30 31 32 33 34 35 36 37 38 AA LL CY Y Y Y Y Y Y Y Y Y Y jio po LY Lo LL LEY LY LL Plant systems Work using subcontracted materials 40 ISO 9001 AQAP 2120 LA NN
66. Supplier when the level of stocks reaches the minimum w 17 10 CONTROL EFFECTED BY OTO MELARA ON THE ACTIVITIES OTO MELARA and its Customers or representatives may carry out audits on the effectiveness and efficiency of the Suppliers Quality System The Supplier must take when and how specified all required corrective actions 17 11 OPERATING INSTRUMENTS The operating instruments are documents whose compilation and management determine the progress of commissioning activities and the warranty service These documents must be presented to OTO MELARA as they e prove the Suppliers operability the state of progress of the activities against the time schedule e allow collecting data for statistical purposes e document the problems that may arise e Supply the elements for correct attribution of failures The types of documents that the Supplier must use include e form for recording and monitoring the requests for intervention attached to procedure OTO MELARA PMQ18 list of work to be performed sheets of work performed test reports situation of changes introduced or to be introduced the repair form attached to OTO MELARA document OTO SR 002 on site modification report attachment B to OTO MELARA document OTO AT 001 intervention report for recording failures and interventions made with measurement of data for availability and reliability attached to OTO MELARA procedure PMQ18 RQAO0001 QUALITY REQUIREMENTS 104 of 110
67. TIVITIES AND DOCUMENTS ACCORDING TO THE CLASSIFICATION 29 TABLE 9 INSTRUCTIONS FOR DESIGN SEE PROVISIONS TO ADOPT FOR DEVELOPING THE DESIGN IN COMPLIANCE WITH OTO MELARA REQUIREMENTS 000000 0 00 000000000000 33 TABLE 10 INSTRUCTIONS FOR COMPONENTS OF OPTICAL AND ELECTRO OPTICAL ASSEMBLIES DESIGNED BY IMHESUPELER 34 TABLE 11 INSTRUCTIONS FOR SOFTWARE rane 34 Table 12 INSTRUCTIONS FOR SCREWS NUTS AND BOLTS 35 TABLE 13 REQUIREMENTS FOR WELD MATERIAL lla 35 TABLE 14 REQUIREMENTS FOR SUPPLIER DEVELOPEDMILITARY PRODUCTS AVAILABLE IN A CATALOGUE 35 TABLE 15 INSTRUCTIONS FOR EQUIPMENT dereio kitir irei e ai eria Ee e Ri a IA r ka Rar A eno iai 36 TABLE 16 REFERENCES FOR COMMODITY CLASSES WHICH REQUIREMENTS ARE REPORTED IN DEDICATED PARAGRAP RE 36 TABLE 17 CORRESPONDENCE BETWEEN THE LEVEL OF THE SUPPLY CRITICALITY LEVEL OF CERTIFICATION OF THE PROCESS OF WELDING OR RESPECT OF RELATIVE 82 FIGURES Figure 1 Example of designation OTO MELARA La Spezia 21 Figure 2 Example of designation OTO MELARA Brescia plant nennen nennen 22 RQA0001 9 of 110 oTo MELARA QUALITY REQUIREMENTS aa A Finmeccanica Company August 2012 QUALITY REQUIREMENTS
68. TO MELARA procedure PF 040 22 e materials supplied by OTO MELARA for subcontracted work must be stored in a suitably identified area according to their characteristics these materials must be permanently identified by means of the associated Withdrawal order materials with a limited life must be handled according to their expiry date materials passed their use by date must be returned to OTO MELARA Materials Management for replacement 7 3 SPECIAL AND OR CRITICAL PROCESSES A special process is defined as a process the results of which cannot be fully ascertained by subsequent product inspections or tests and defects of which are only revealed when the product is put into use or after it has been installed and has been subjected to use and or after some time from its delivery or commissioning with permanence of the product in the environment of intended use A critical process is defined as a process that if not correctly carried out can induce risks for personnel safety and product integrity a critical process can be also a special process OTO MELARA considers the following processes as special welding and braze welding heat treatments gluing painting surface treatment wiring of electrical equipment hand and wave soldering of printed circuits surface assembly soldering forming of composite materials Non Destructive Tests NDT it s considered special and critical the process of ammunition production For these processe
69. TRIX OTO MELARA AND 2 2 2 2 15 5 OTOMELARA REQUIREMENTS IDENTIFICATION AND CORRELATION WITH SUPPLIER S QUALITY MANAGEMENT SYSTEM 19 5 1 E Iewiem 19 5 1 1 diuisa IVO C H 19 341 2 Commodity classification in terms of quality requirements eese sess 20 5 2 CRITICAL CHARACTERISTICS IDENTIFICATION ON DRAWINGS 23 5 9 SUPPLIER QUALITY SYSTEM LEVEL isa 23 5 3 1 Sub Suppliers Quality System level ii 23 5 4 DESCRIPTION OF MELARA COMMODITY 5 5 5 1 25 5 4 1 Non metallic indefinite materials A iii 25 5 4 2 Functionally important non metallic materials 25 5 4 5 Welded structures and mechanical components C iii 25 5 4 4 PD OO 25 5 4 5 Work using subcontracted materials E iii 26 5 4 6 Metallic indefinite materials and unfinished products F iii 26 5 4 7 TOP 26 5 4 8 Forged and moulded parts HD iii iia 26 5 4 9 Electrical control panels consoles I 26 5 4 10 ML ila 26 5 4 11 Wena maten RR EEE REI 26 5 4 12 CHAD 26 5 4 13 Electri
70. ality of any non RQA0001 47 of 110 MELARA QUALITY REQUIREMENTS a A Finmeccanica Company August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A compliance found on its supplies to OTO MELARA in order to jointly assess the severity major or minor and the possibilities of acceptance For supplies that have been made according to drawings and or specifications of the Supplier i e for which the Design Authority is the Supplier it must notify OTO MELARA about any non compliance which has impact on fit form function performance safety and spare parts For the resolution of the non compliance the Supplier must submit to OTO MELARA Quality a reasoned request for acceptance in waiver or concession containing at least e identification of the defective materials e description of the defects found or of the deviation e related causes e the proposed containment actions repair restoration of defective materials e the proposed corrective actions to prevent recurrence of the phenomenon This request once approved by OTO MELARA Quality shall be recorded on the Certificate of Conformity relating to the materials in question w oupplies single or batch affected by major non conformities will be rejected in their entirety In the case of supplies with one or more minor non conformities OTO MELARA will apply the criteria for acceptance or rejection as defined in paragraph 7 7 5 2 Regular meetings
71. als A hose pipes for compressed gases flux gases oils or fuels elastomers structural adhesive blocking thread adhesive synthetic materials nylon Viton amp PTFE etc composite materials sheaths gaskets power cables painting products 5 4 2 Functionally important non metallic materials B Crew seats and protections domes flooring panelling and armouring made of composite or ceramic materials 5 4 3 Welded structures and mechanical components C Turret casing ballistic protections frames mountings etc parts made from indefinite materials for chip removal cold forging bending rolling etc 5 4 4 Plant systems D An assembly of interconnected components and subassemblies assembled functionally and or physically to form a functional logic unit for the purpose of achieving a performance RQA0001 26 of 110 oTo MELARA QUALITY REQUIREMENTS a A Finmeccanica Company August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A 5 4 5 Work using subcontracted materials E Activities performed by the Supplier using its own equipment and resources on materials belonging to OTO MELARA or End Customer Applicable also for Special Processes execution only To this class belong also partial activities carried out by Suppliers within a OTO MELARA internal production process w 5 4 6 Metallic indefinite materials and unfinished products F Sections extruded items laminated material p
72. be complied with by the Suppliers supplying OTO MELARA with ammunition and or parts thereof made to OTO MELARA s specifications If the supply contains parts designed by the Supplier the PROJECT REQUIREMENTS see TABLE 9 subsection PROVISIONS TO ADOPT FOR DEVELOPING THE DESIGN IN COMPLIANCE WITH OTO MELARA REQUIREMENTS and SOFTWARE REQUIREMENTS see TABLE 10 subsection SOFTWARE shall apply In particular the process validation and control requirements including quality records are defined Refer to subsection APPLICABILITY above for instructions on how to handle the supply of ammunition 14 1 1 Quality System Organisation For the kind of product and relevant activities the Supplier Quality System shall comply with AQAP 2110 or ISO 9001 2008 if the supply doesn t contain parts designed by the Supplier or AQAP 2120 or ISO 9001 2008 if the supply doesn t contain parts designed by the Supplier In addition in the event that it is required to supply particular software application packages to be integrated for example in self guiding systems or piloting in flight of smart ammunitions designed by OTO MELARA compliance with AQAP 2210 is required 14 1 2 Complex critical products Within the framework of the supply of ammunition to OTO MELARA the following products are defined as complex critical shell blank empty shell charged shell warhead casing charged warhead case igniter propellant fuse or initiators electronics and homin
73. c form for WPAR PQR shall be used to record all weld details validity and test results w 13 4 CONTENTS OF THE WPAR PQR The WPAR or PQR prepared and approved by the entitled professionals must contain the following information General e Reference WPS used for test specimen execution e Personal data of the welder first second name date and place of birth Specific e Test specimen details and approval validity filed for the following parameters welding process plate pipes weld joint type base material group filler metal shielding gas or flux dimensions thickness external pipe diameter welding position e Tests Test shall be established and carried out by the examiner or by the examiner body and shall comprise visual inspection applicable NDC fracture and bending test additional tests the laboratory certification shall be attached if required For each test and or proof shall be specified which one has been carried out and passed Place date of issue and expiry stamp and signature of the manufacturer shall be also reported 13 5 SPECIAL RULES FOR BALISTIC MATERIALS All the welding procedures must be performed in compliance with the relevant specifications and in suitable environments temperature and humidity values matching the requirements of the standards covering the features of the specific materials to be welded Before starting welding operations the above materials must be stored for at leas
74. cable requirements the assessment of the root causes of every non conformity and the effective corrective action taken As part of the Aeronautical supplies the FAI must be performed on all products except for catalogue products The recognized reference standard is the standard SAE AS EN 9102 Aerospace series Quality systems First article inspection For aeronautical products 100 verification of drawing characteristics is required for other products it is possible to identify by agreement with OTO MELARA the characteristics to be verified The FAI is the inspection of the first product sample made and must be carried out in the stage at which it is possible to verify its respect to the envisaged configuration the compliance with the documentation which defines requirements and that all envisaged activities have been carried out and the correlated documentation has been prepared and defined in such a way to ensure repeatability of the manufacturing and control operations If the product supplied is an assembly documentation shall report evidence of any constituting parts The FAI highlights details that are not visible and it is also the first verification of the correct manufacture of the product The FAI result based on extensive documentation submitted by the Supplier or made in the presence of OTO MELARA staff and possibly of the final Customer is binding for the continuation of the series production It will not be possible to proceed
75. cal and electronic components O ii 26 5 4 14 Optical and electro optical components and assemblies 26 5 4 15 OE ENS 26 5 4 16 LOI A 26 5 4 17 Hydraulic or pneumatic components S iii 27 5 4 18 Activities performed by Suppliers at the OTO MELARA plant internal 22 2 0000000005022 27 5 4 19 Services rendered by Suppliers at the Customer s facility external U 60600000001 27 5 4 20 Catalogue commercial parts mechanical V enne nn nennen nennen senes 27 5 4 21 Supplier developed military products available in a catalogue W essen 27 5 4 22 LA oaapeceeiae2 27 all Mahne COU DING ire 27 SEC O IA ica 27 EI HABET 27 LEI 28 6 SYNOPTIC TABLES FOR COMMODITY CLASSES WITH RELEVANT REQUIREMENTS FOR ACTIVITIES AND DOCUMENATION REQUESTED WITH THE SUPPLY AND RELATED TO THEIR CRITICALITY LEVEL 28 7 DEFINITIONS AND GENERAL 2 22 37 7 1 IDENTIFICATION AND 37 RQAO0001 5 of 110 7 MELARA QUALITY REQUIREMENTS 2 August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELAR
76. ce e the number and type of the personnel involved In the event of delay in developing these activities that is attributable to the Supplier it must present in the program revision the steps it intends to take to solve the problem Any documents consigned by the Supplier to OTO MELARA unofficially and not explicitly referred to in the contract documents relating to the types of documents that the Supplier is responsible for issuing must be considered as application examples and the Supplier may not use them for developing its own activities or referring to them in its documents w 17 4 ORGANISATION OF THE SUPPLIER S PERSONNEL AND RESOURCES In case of activities over which the Supplier has complete responsibility it shall set up a structure comprised of the following e a person responsible e Spare parts management operator e Skilled servicing engineers maintainers The person in charge will have the following tasks co ordinating the personnel and planning their work handling relations with the Customer s personnel present on site handling relations with OTO MELARA s personnel handling relations with Suppliers for resolving non conformities delays in delivery etc The person in charge must provide OTO MELARA in real time and in the manner established in the Quality Plan documents detailing the problems occurring with the equipment during operation regardless of whether or not they are reported by OTO MELARA s Client an
77. cocfm 16 2 SUPPLIER S ORGANISATION AND PERSONNEL The Supplier must guarantee the continuous presence in the department of a contact person in possession of the necessary qualification and technical skill to create the interface with the person responsible for OTO MELARA The name of this person shall be formally notified to OTO MELARA Procurement before starting the activities integrated by his her up to date Curriculum Vitae The Supplier must guarantee that the work is carried out by trained and qualified personnel at OTO MELARASs site In the field of aeronautical products the suitability of personnel should be also attested by the Supplier Quality which upon request must provide evidence that the personnel members are trained on the procedures to apply and are aware of them Such personnel must also be evaluated in advance by the Production and OTO MELARA Quality 16 3 DEVELOPMENT OF THE ASSIGNED ACTIVITIES The Supplier undertakes to develop the activities assigned following the established work and control instructions using equipment that is suitable in terms of class type and maintenance status In particular it cannot use equipment not conforming to the applicable safety law directives The activities shall be performed according to the set schedule and the Supplier must promptly inform OTO MELARA focal point of any difficulty or impediment that may affect such compliance When required Supplier personnel shall fill the progres
78. control and self checking g specify the sampling plan h show for each stage the spaces that can be used by the Supplier by OTO MELARA and by the Customer to indicate their own binding points and or notification points i show the Witness Points called W POINTS a witness point is a stage of activity of which OTO MELARA must be informed at a set time in advance j show the Binding Points called POINTS a binding point is a stage of activity requiring the presence of OTO MELARA k show the Report Points called R POINTS a report point is a stage of activity requiring the issuing of a test report See for example what reported in attachment 3 Y RQA0001 4 MELARA QUALITY REQUIREMENTS 04 A Finmeccanica Company August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A 8 6 1 Visual Dimensional inspection Certificate The certificate form or report shall attest the positive outcome of visual and dimensional inspection and list the results of check of those key characteristics agreed with OTO MELARA and reported in MCP for item product acceptance For aeronautical products subjected to FAI what is reported in the dedicated paragraph applies Characteristics are Dimensions reported in the drawing Drawing notes referring to the material that constitutes the part Drawing notes describing heat and surface treatments or other parameters i e tightening torques etc lf detailed indication are not availabl
79. cord the results of this check together with all the test results 14 1 3 5 Product handling The products must be handled in compliance with the contract requirements and the applicable provisions of law in order to protect the product and the personnel involved right from when the material enters the factory throughout all the manufacturing control stages up until final delivery 14 1 3 6 Packing and identification box marking The products must be packed in compliance with the requirements set out in the technical documentation supplied by OTO MELARA OTO MELARA s Specifications Drawings and RQA0001 91 of 110 oTo MELARA QUALITY REQUIREMENTS e A Finmeccanica Company August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A Purchase Order and in compliance with the provisions of law Compliance of the Packing and identification must be verified by the Suppliers Quality function that shall record the results of this check together with all the test results Unless already included in the Quality Plan or the applicable documentation the Supplier must submit to prior approval by OTO MELARA the packing box identification and marking criteria for approval w 14 1 3 7 Despatch to Final Customer The material cannot be despatched before successful completion of the check of the packaging its marking and identification and the accompanying documents This compliance shall be verified by the Suppliers Quality function
80. criptions reported below a Pickling The treatment is intended to remove slag or dross that form as a consequence of high temperature heating in presence of oxygen as for example hot rolling forging heat treatment welding etc The techniques can be mechanical or chemical b Passivation This treatment called also decontamination is used to restore the natural passivity of the stainless steel surface eliminating traces of different metal such as carbon steel and preventing the surface to show stains even if in not severe environment The use of tools that have machined carbon steels such as grinders or storage in contact with carbon steel can contaminate the stainless steel surface To prevent contamination consequences it s necessary to decontaminate the parts it can be done chemically on the whole surface immersion or locally with special paste available on the trade 13 7 RESISTANCE SPOT WELDING STITCH WELDING Resistance Spot Welding RSW is a process by means of which only the base material is molten through direct current passage The procedure shall be defined described and documented as per GENERAL REQUIREMENTS FOR WELDED JOINTS AND UNWELDED MECHANICAL ELECTRICAL CONNECTIONS with the relevant content The Suppliers welder has the job to co ordinate and provide support in preparing the specimens for assessing the processes and the welding machine carry out the tests on the welded joints and co ordinate the welders ac
81. d In case 1 The Supplier must ensure that OTO MELARA s time schedule is met regardless of whether the product is replaced at OTO MELARA s facilities in compliance with the rules for those working inside the factory or on its own premises 7 11 REWORK OR REPAIR ACTIVITIES RELATED TO NON CONFORMING PRODUCTS FOUND AT OTO MELARA s OR AT CUSTOMER s 7 11 1 Receipt The Supplier must draw up a report on the state of any non conforming materials products returned by OTO MELARA Materials Products under warranty must be accompanied by the Non Conformity Report for Subcontracted Supplies In other cases the Supplier must follow the instructions shown on the rework repair order Within its own factory the Supplier must treat such products as if they were materials supplied by OTO MELARA in subcontracting and identify them as non conforming units 7 11 2 Ascertainment Record for materials belonging to the Customer under repair or servicing In case the Supplier is requested to carry out servicing repairs or updating materials belonging to OTO MELARA Customer it shall issue an ascertainment record signed by OTO MELARA charged personnel and by the Customer when required about the status of the materials at receipt That record shall be filed and delivered to OTO MELARA together with test documentation 7 11 3 Rework and Repair Rework and repair activities carried out in relationship to what indicated by OTO MELARA and what
82. d the corrective maintenance activity carried out The person in charge must also answer requests for details from OTO MELARA s personnel or anyone working for it The name of the person and an up to date curriculum must be specified in the Quality Plan The Supplier must guarantee at OTO MELARA s the use of properly trained and if necessary qualified personnel that are able to e interpret the technical documentation correctly e carry out their tasks autonomously e develop the assigned self control activities e highlight any non conformities in the components received or when performing their tasks e follow the safety rules in order to prevent risks to him herself and anyone else present on site RQA0001 101 of 110 oTo MELARA QUALITY REQUIREMENTS a A Finmeccanica Company August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A The Supplier agrees to develop the activities in accordance with legal requirements and with the operating and control instructions and the use and maintenance handbooks and using equipment that is suitable in terms of class type and maintenance status In particular the Supplier must not use equipment that does not comply with the current safety directives The measuring equipment must be calibrated periodically according to ISO 9001 2008 and ISO 10012 and show evidence of its validity status furthermore the Supplier must present documentation showing the measurements made w 17 5 SU
83. delivered before the commencement of commencement of activities activities 10 Certification of special For info through Supplier For verification and For info for Supplier List process and personnel list approval prior to update employed in including NDC commencement of activities 11 Acceptance test procedure to For verification and be delivered before the approval prior to commencement of activities commencement of activities 12 Request for deviation waiver For action from of set requirements To be jointly with Design presented when necessary For info For info department surely before presentation to final acceptance STQ Technical Services of Quality only at La Spezia plant 5 QPM Quality Program Manager RQA0001 OTO MELARFA QUALITY REQUIREMENTS 17 of 110 04 A Finmeccanica Company August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A TABLE 3 DOCUMENTS ISSUED BY THE SUPPLIER THAT IMPACTS ON DESIGN For info proposed whenever deemed necessary 16 17 Design review documentation 10 work days before the date of the event 18 Technical documentation certifying validation of own design products 19 Own design product For info configuration included in OTO MELARA product baseline 20 Proposals for Modification to For info own design products included in OTO MELARA products 21 Notification of wi
84. der To make it possible to issue a purchase order it is necessary that the Supplier status is recorded as active in the List This means that the Supplier is eligible to provide products or services to OTO MELARA Active suppliers are classified in the OTO MELARA Supplier List in two main categories a approved suppliers including e authorized Producer or Dealer of catalogue products standard parts consumables that may influence the quality of the product oil grease paint tools etc technical and maintenance services related to the production line e qualified Suppliers whose supplies are related to products processes or services intended to be integral part of OTO MELARA s products or be used for their logistic support v qualified for products classifieds as criticality level see Table 5 v qualified for products classifieds as criticality level 2 see Table 5 Y qualified for products classifieds as criticality level 1 see Table 5 a approved suppliers under a condition In general this type includes suppliers for which conditional approval is required which is performed by setting appropriate points of attention such as the binding presence of OTO MELARA personnel to particular processing phases testing by OTO MELARA supply of documentation according to certain standards etc Depending on the severity of the situations that arise in the course of the audits and tests the Suppliers can be removed suspended from
85. e identification analysis check and mitigation i RQA0001 56 of 110 MELARA QUALITY REQUIREMENTS 25 August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A 8 5 CONFIGURATION MANAGEMENT PLAN Configuration Management activities must be carried out in accordance with the requirements of applicable NATO standards AQAP 2110 AQAP 2120 AQAP 2130 AQAP 2210 Unless explicitly stated on the Order the Supplier may associate the Configuration Management Plan with the Quality Plan to be submitted to OTO MELARA for approval within 60 calendar days of the acceptance of the Order and prior to commencement of the activities This Plan must set out the procedure governing the flow of information between the Supplier and OTO MELARA and develop the following requirements in particular applicable according to the type of supply Identification of the Configuration Configuration Control Configuration Status Accounting Configuration Audit The following must also be described depending on the applicable AQAP standard a the criteria for selecting Configured Articles only if AQAP 2110 is applied b the methods for identifying the technical documentation drawings lists and the ltems only if AQAP 2110 is applied c the methods for issuing and managing Baselines only if AQAP 2110 is applied d the methods for classifying modifications and waivers deviations e the methods of sendin
86. e description filled also with sub supplied activities indicating sub Supplier name 1 Reference Documentation Code including revision index to carry out the planned activities at the stage i e manufacturing cycle code o 8pPlicable WPS number applicable test procedure code Record the type of control to be executed i e functional visual dimensional etc and the percentage of item to check M M 11 14 Declaration of completion of the stage signature of the responsible i persone SS 15 Definition of intervention points of QA of the Supplier of the Customer OTO Melara of the final Customer to be associated to phases stages I classification 16 Phase Classification hold point W witness point 222200000000 R recoding report 17 Control phase execution date 18 Inspector signature L A LJU U LA 19 Number of the document issued for the specific phase i e test report certificate of conformity etc 20 Record possible notes and reference of non conformity report or deviation e 2 R A AA A A A A Code RQAO0001 n Em 107 of 110 04 Page Rev QUALITY REQUIREMENTS MELARA August 2012 Date A Finmeccanica Company lt o lt De lt O H O O E YN l n n gt o De O LL o E oe 2 O
87. e developed a With reference to AQAP 2110 ISO 9001 2008 AQAP 2210 EN AS SJAC 9100 2009 for aeronautical supplies standards it is necessary to meet the requirements regarding design and development planning input elements output elements review verification validation and control of modifications If the supply includes software see also subsection SOFTWARE b The product must be developed and properly documented according to the applicable standards and with reference to the planning under the Quality Plan and the Configuration Management Plan c n case of low complexity products or not safety critical OTO MELARA Quality department will define with the Supplier possible deviations to the present document that will be dealt with in the Order and described in the Supplier s Quality Plan 11 1 GENERAL If the Order requires design activities to be developed the Supplier must a make sure of being in possession of the physical functional and performance interface requirements for the product to supply b define in a Technical Specification for design purposes and the internal requirements traceable as well as higher level requirements c identify the critical and key design elements according to OTO MELARA criteria subsections Criticality Level and Commodity classification in terms of quality requirements d develop and send OTO MELARA within 60 calendar days from the Order receipt a Project Plan of the Design development a
88. e the criterion for determining the dimensions to be recorded is the following in case NC machines are used for production of that part the lot produced can be considered as follows machine obtained To be recorded in the Last part and some dimension form or certificate intermediate pieces To be recorded in the form or certificate Operator To be recorded in the Show in the form or responsibility form or certificate certificate the results 124 of the checks carried out on all the products manufactured dimension In case the machine does not give confidence in dimension repeatability key dimensions shall be checked for all machined parts Note if the last piece checked is out of tolerance it is necessary to check all the pieces produced from the last inspection with positive result The certificate shall report at least Supplier s logo or name Part Number Part serial Number Reference to NC machine part program when applicable Identification of the characteristic on the drawing characteristic nominal dimension and relevant tolerance measured value instruments used with indication of calibration expiry date see also paragraph TEST AND PROCESSING INSTRUMENTS EQUIPMENT applied process i e heat surface treatment NDT etc acceptance responsible signature Machine obtained dimension dimension obtained through machine precision and repeatability i e the distance bet
89. e the software activity development program and the expected dates of delivery of the documents required Table ll establishes the types of documents required with a brief indication of their contents and whether OTO MELARA approval is required or not Table Ill details the application of the activities and documents according to the awareness w level required and depending if the software product is included or not in a complex system weapon system 12 10 WORK PRODUCTS The following sub sections report the deliverable Key Work Products which are elements to be consigned in a system software acquisition 12 10 1 Definitions The Work Products WP referred to in this document are documents and other items produced and used by the Supplier to design build test validate deliver and maintain the software or other equipment defined here that contains software Work Products can be divided into three main categories e OR Organisation Work Products are produced and used by the Supplier as general and standard guidelines for all projects together with rules of application adaptation e PR Project Work Products are generate to plan control and verify various stages of the defined project e RE Result Work Products recorded are the result of the performance of all the activities of a defined project They confirm that the activities are performed in accordance with the contents of the Pr
90. ed to AER Q standards the Quality Plan shall be in accordance with AER Q 140 w 3 The Supplier will be subject to periodic audits by OTO MELARA Quality and by its Customers or their Representatives when required of its Quality System and to an assessment of it in terms of supplies Vendor Rating The Supplier must implement any corrective actions as and when required 5 4 DESCRIPTION OF OTO MELARA COMMODITY CLASSES Description of the CLASSES Note the applicability of quality requirements of this document requires items categorisation through drawing where classification can be reported drawing legend or a list or other document referenced to Bill of Materials or the specific indication in the Purchase Order following the indication reported by the requiring party in the request for purchase form that make explicit and available that information thus determining the requirements It is evident that for example classes D E M V dealing with standard parts indefinite materials or incorporeal objects as for class Q software may not require a drawing intended as a graphic representation of the object but merely as a support where particular requirements or univocal definition of the Qualified Supplier can be reported In any case for an appropriate purchase order management it is mandatory that the category the ordered item belongs to is properly identified 5 4 1 Non metallic indefinite materi
91. edule set out in the Project Plan or for any failure in performing the required activities by applying the methods and entities specified on the order For active participation in the Design Reviews OTO MELARA Design and Quality Dept shall receive the documents subject to valuation at least 10 working days in advance Attendance to the meetings tests Design Review and document approval by OTO MELARA personnel does not relieve the Supplier from its design liabilities as regard contract and legal obligations 11 3 RAMS Reliability Availability Maintainability and Safety and LCC Life Cycle Cost REQUIREMENTS For installations systems and assemblies the RAMS LCC qualitative and quantitative requirements that the object of the supply must meet are specified in the RAMS LCC specification issued by OTO MELARA Besides the requirement values this specification indicates the mode of development of the RAMS LCC analyses to provide If this Specification is not issued by OTO MELARA the supply shall comply with the following standards EN 50126 national and European market MIL STD 882 MIL HDBK 470 USA market STANAG 4174 and ARMP NATO procedures only if required in the contract In general the required documentation includes as applicable a Safety Analysis divided in phases as per MIL STD 882 b Reliability forecast analysis format and contents to be agreed on with OTO MELARA C FMEA FMECA analysis format and conte
92. el are present at the Supplier s facility Even when OTO MELARA and the Customer do not attend tests and inspections but accept the supply on the basis of presented documents this does not relieve the Supplier from product liability or from complying with the contract specifications Inspections and tests performed by OTO MELARA and or the Customer do not relieve the oupplier from its obligation to eliminate any defects or inconveniences found in order to conform with contents of the subcontract documents The Supplier must guarantee the following in the conduction of tests and inspections a the use of suitable and where applicable qualified personnel b the use of test instruments and equipment of a suitable type and class submitted to periodical calibration in accordance with the applicable standards c the use of test methods approved by OTO MELARA The activities connected with development of the contract order assigned to the Supplier and its Sub Suppliers may at any time be subject to conformity verifications and checks by RQA0001 43 of 110 oTo MELARA QUALITY REQUIREMENTS a A Finmeccanica Company August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A OTO MELARA and the Customer in order to prove compliance with all the contract specifications in terms of methods procedures and documentation in general w 7 7 2 Inspections and tests at the Supplier s or its Sub Suppliers supervision by OTO
93. elow IDENTIFICATION OF THE PRODUCT AND MANUFACTURER a composition information on the ingredients IDENTIFICATION OF HAZARDS b first aid measures fire preventing measures measures envisaged in the case of accidental leakage handling precautions exposure individual protection physical and chemical properties stability and reactivity toxicological information ecological information disposal conditions information on transportation other information 3 RQA0001 60 of 110 oTo MELARA QUALITY REQUIREMENTS a A Finmeccanica Company August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A The data must be shown on the label in compliance with the rules on classification packing and labelling of hazardous products w 8 10 CERTIFICATION OF CONFORMITY TO OTO MELARA PURCHASE ORDER The aim of the Certificate of Conformity is to state under the direct and exclusive legal liability of the Supplier that the supply complies with the technical and regulatory requirements specified in the purchase order and in the documentation referred to therein The statement must be undersigned by the Suppliers legal representative or someone else belonging to the Suppliers organisation who has specific powers for the purpose Quality Manager The Certificate of Conformity must contain at least the following elements Supplier s company name address of the manufacturer s plant reference
94. ent designed by the Supplier under its responsibility available on demand in accordance to the applicable European Directive 113 TC Test Certificate 114 ATP Acceptance Test Procedure and relevant Test Report 115 UM User Manual Parts list etc in accordante to the applicable European Directive 116 QSL Quality System Level to be applied 17 Includes also used in previous versions of this document up to 0001 02 118 QSL For equipment YM if designed by the Supplier ISO 9001 AQAP 2110 AQAP 2210 If produced on the basis of Technical data package produced by OTO MELARA ISO 9001 AQAP 2120 RQA0001 MELARA QUALITY REQUIREMENTS d of 110 A Finmeccanica Company 5015 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A 7 DEFINITIONS AND GENERAL REQUIREMENTS w Additional requirements specific for an order can be established by OTO MELARA in separate documents which will supersede this document Therefore should a conflict with this document arise the Supplier shall conform to the specific document The following paragraphs besides defining general requirements have the aim to give an agreed meaning to terms and definition used in this document For all other cases ISO 9000 2005 e NATO AQAP glossaries apply For Aeronautical Products the EN AS JISQ9100 requirements which prevail over what is reported in the following paragraphs apply 7 1 IDENTIFICATION AND TRACEABILITY 7 1
95. entioned paragraphs 1 2 3 4 5 7 8 9 apply TYPE OF PRODUCT OR Code Sec SUPPLY 17 Non metallic indefinite materials gt OO metallic materials A mechanical components Plant systems A EE subcontracted materials fanduntnished products II S S ES and unfinished products Castings 00 ENEMIES a Electrical control panels consoles Nuts bolts and screws get MEE RE Complete assemblies assemblies a c NAM and electronic a components Optical and electro optical It components and assemblies Software Q x ee ol _ 1 ___ 2_ Activities performed by T Suppliers at the OTO MELARA plant internal ors Suppliers at the Customer s facility external V Catalogue commercial parts The table below constitutes a matrix between the types of supply the class of goods code mechanical Supplier developed military products available in a catalogue Equipment Y x xk x x xe Equipment Code 0001 Page 12 of 110 MELARA QUALITY REQUIREMENTS A Finmeccanica Company Date August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A 3 REFERENCE STANDARDS FOR SUPPLIERS QUALITY MANAGEMENT SYSTEMS w Reference Standards are those ones that apply in the context in which OTO MELARA operates and they must cover fields of ap
96. environment vibrations shocks etc e fire resistance The test method is defined according to military and other standards as specified in the general requirements for the product The tests required for product validation must be carried out on a representative sample only for the purposes of configuration and series production and only on that Negative test results must trigger the design corrective action procedure or the performance of additional suitably documented tests The type tests must be defined in the quality plans identifying those to be repeated periodically in order to verify the preservation of the characteristics and performance of the production line coop 7 9 MANAGEMENT OF NON CONFORMITIES FOUND BY THE SUPPLIER A non conformity is any departure of a product from the requirements set out in the technical documentation referred to on the order contract The Non Conformity Report NCR is a document identifying and recording product non conformities whose required quality evidence is indeterminate or unavailable or does not correspond to the applicable specifications or drawings referred to in the order For supplies that have been made according to the drawings and or OTO MELARA specifications i e for which the Design Authority is OTO MELARA or in the case in which OTO MELARA represents the gateway to another Design Authority as for products manufactured under license the Contractor shall notify OTO MELARA Qu
97. es Strategy 9a Re utilisation plan emo OO n gu 10a Acquisition Plan System Requirement Pe fede de dade 11a Software Requirement Specification 4e Sotware Design Spedicaton x x x x x x Software Design Test Validation Strategy 14a Test Validation Plan Unit Test Strategy 15a Test Plan general Integration Test Strategy 16a Integration Test Plan Software Validation Sofware at ME Test Strategy 18a System Test Plan No Regression Test Strategy of the performance x x 19a Non Regression Test Plan RQA0001 81 of 110 OTO MELARA QUALITY REQUIREMENTS 04 Finmeccanica Company August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A L 1 Acceptance Test Strategy X 20a Acceptance Test Plan x 21 Test Procedures general SWISYS SWSYS SW Test Report general SW SYS SWISYS SWISYS MANE Strategy Configuration Management Plan MPEG 24a Software ET x X x X x X x X Change Request 00 Change Control Documents 1 231 1 27 Maintenance Strategy Plan xo x x Customer Support Documentation ala X Software Version Description x x x Document RQAO0001 82 of 110 7o TO MELARA QUALITY REQUIREMENTS 2 August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A 13 GENERAL REQUIREMENTS FOR WELDED JOINTS AND UNWELDED
98. esponsible of design does not envisage the need of CE marking unless required by OTO MELARA in the order the equipment fixture shall conform with documented evidence with what reported in attachments 5 6 and 7 of Decreto Legislativo 9 aprile 2008 n 81 That evidence shall be sent to OTO MELARA together with documents required by law and by Table 15 of this document For electric equipment European Directives always apply 10 2 CE MARKING CE marking considered as a proof of the positive outcome of design manufacturing and testing regulated activities duly documented is necessary for use in OTO MELARA facilities or for sale of equipment that can be considered comparable to a machine including lifting or load conditioning gears equipment subject to pressure electric equipment The CE label once affixed attests the conformity of equipment electric equipment with applicable Directives and its safe usage As a general criterion the Supplier shall affix CE marking in accordance with applicable directive minimum requirements and is bond to a preventively verify at specification and or design phase equipment conformity with safety essentials requirements as per applicable Directive b issue a declaration of conformity that shall be delivered together with the product C prepare a Technical Dossier in accordance with applicable Directive that shall be maintained and available according to law d prepare an Use
99. fication and the accompanying documents This compliance must be verified by the Supplier s Quality function that must record the despatch together with all the test results w The Supplier must despatch the material in compliance with the order requirements after having received formal authorisation from OTO MELARA The Supplier is responsible for getting the couriers to comply with all the rules and regulations regarding ammunition as prescribed by the applicable law or the technical documentation supplied by OTO MELARA 14 2 2 Test documentation and certification of the supply At the end of the acceptance test of the object covered by the order the following documents must be sent to OTO MELARA a Certificate of Conformity of the supply signed by the Quality function or the Head of the company drawn up in accordance with the form referred to in Annexe B of AQAP 2070 b copy of the certificates of conformity of any lot batched components c copy of the required test recording forms d identification codes of the products materials included in the supply containing dangerous substances under the REACH Regulation and the related safety data sheets These test and conformity certificates together with the Quality Plan and the Manufacturing Control Plan shall be filed and kept by OTO MELARA Quality 14 2 3 Ammunition destined to OTO MELARA tests In this case the Supplier must ensure under its full responsibility the
100. for some programs can be integrated with further requirements For some contracts when specified RQA0001 44 of 110 oTo MELARA QUALITY REQUIREMENTS d A Finmeccanica Company August 2012 in the Purchase Order the Government Quality Assurance is carried out in accordance with STANAG 4107 Mutual Acceptance of Government Quality Assurance and Usage of the Allied Quality Assurance Publications and NATO AQAP 2070 NATO Mutual Government Quality Assurance GQA Process w 7 7 4 Work Progress Monitoring Supplier and its Sub Suppliers shall make available all means and assistance so that the Organizations tasked by OTO MELARA can carry out the work progress monitoring bearing in mind that the respect of the deliveries is monitored by the Materials Management while the correct execution of the manufacturing and control phases is monitored by OTO MELARA Quality Consequently Materials Management is the interface with the Supplier for the possible supply of materials and equipment in manufacturing account for the management of the product baseline drawings part lists and any requests for changes and for all the logistic aspects of the shipment and delivery of the finished product On the other hand Quality is the interface with the Supplier for approval of construction documents prepared by the Supplier plans and procedures and for managing every quality aspect of the supply including the management of any non compliance and
101. formity certificates shall be filed and kept by OTO MELARA Quality RQA0001 MELARA QUALITY REQUIREMENTS 9 of 110 A Finmeccanica Company August 3015 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A 15 USER MANUALS AND SPARE PARTS CATALOGUES i g Refer to subsection APPLICABILITY above for instructions on how to handle the supply of user manuals and spare parts catalogues This chapter refers to products designed and developed by Suppliers on the base of OTO MELARA requirements Note In case of catalogue products developed by Suppliers the required documentation is the standard one unless otherwise agreed in OTO MELARASs order 15 1 GENERAL REQUIREMENTS The Suppliers of plant systems and equipment shall deliver OTO MELARA Logistic Business Line the structured product documentation for verification and approval so as to include a general description of the system plant covered by the supply link with the reference configuration link with maintenance plan functional description of the system plant within the execution of the job order preventive and scheduled maintenance corrective maintenance setting and adjustments installation trouble shooting overhauling procedure opare parts catalogue containing the figures assemblies subassemblies list and relevant parts exploded isometric drawings 15 2 DOCUMENT DEVELOPMENT METHOD All the above documents must be supplied wit
102. ftware see also subsection PROVISIONS TO ADOPT FOR DEVELOPING THE DESIGN IN COMPLIANCE WITH OTO MELARA REQUIREMENTS If the supply consists of software only the Supplier must guarantee the use of life cycle model organised in accordance with AQAP 2110 ISO 9001 2008 EN AS SJAC 9100 2009 for aeronautical supplies AQAP 2210 ISO IEC 12207 and ISO IEC 9126 standards including at least the stages described below Anyway making reference to AQAP 2110 ISO 9001 2008 AQAP 2210 requirements related to design and development planning input elements output elements review validation and change control shall be satisfied The methods and organisation with which the Supplier intends to develop its activities must be defined in a Quality Plan with the Configuration Management Plan attached to it 12 1 SOFTWARE REQUIREMENTS All the software requirements must be defined and documented in a software requirement specification The specification shall trace the requirements defined at upper level by OTO MELARA This document must describe the performance architecture and make up of the whole software design and contain a block diagram showing single elements of the software configuration modules and their connections Unless specified otherwise a system control status diagram must also be included 12 2 SOFTWARE IMPLEMENTATION In this stage the Supplier must define the software architecture identify and specify the software modules and write the c
103. g major modifications and waivers deviations to OTO MELARA for approval f The methods of sending minor modifications and waivers deviations to OTO MELARA for verification of their correct classification w 8 6 MANUFACTURING AND CONTROL PLAN MCP The Manufacturing and Control Plan is the document with which the Supplier plans the production process identifies the tests and inspections to perform and details the methods and the acceptance criteria This document must be approved preliminarily by OTO MELARA and the binding points requiring attendance by OTO MELARA s and or the Customer s personnel must be identified The MCP must where applicable a contain elements identifying the document the number the subject the dates of issue and revision details of the product to which it refers and approvals b list in sequence the macro stages of manufacture and control and show references to the related documents drawings technical specifications procedures work cycles control cycles WPSs defined as manufacturing dossiers c clear indication of those phases operations intended to be assigned to sub Suppliers and their certification level with the evidence of the relevant control d list the tests and certifications specified in the applicable technical documents e contain adequate certification concerning visual functional inspection and dimensional checks f indicate the persons responsible for performing the various stages of
104. g section luminous tracers flash charge sabot explosive charge complete round transport box DOSRZTATTTa DAOTD 14 1 3 Manufacturing and control process requirements 14 1 3 1 Manufacturing and control plan The provisions under subsection MANUFACTURING AND CONTROL PLAN MCP shall apply with the following addition RQA0001 90 of 110 oTo MELARA QUALITY REQUIREMENTS a A Finmeccanica Company August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A a for each type of supply when first implementing the relevant manufacturing control plan OTO MELARA personnel shall perform a process audit b for each supply before starting the activities it is necessary to send to OTO MELARA possibly together with the Quality Plan the manufacturing and control time schedule the chart listing the parts making up the supply the Product Baseline and all the elements required to ensure trace ability e g the internal job number sales order number w All the above must fully comply with the manufacturing requirements included in the technical documentations drawings special process specifications ammunition specifications supplied by OTO MELARA The manufacturing documents shall also ensure trace ability of the ammunition components Important note the test instructions procedures shall match those specified in the technical documentation supplied by OTO MELARA ammunition specifications drawings and part lis
105. gue commercial parts mechanical V Commercial mechanical parts functionally important reported in dedicated catalogues such as MIL specifications with part number beginning with MS AN NAS shall be produced by Qualified Producers listed see https assist daps dla mil Those parts shall not be altered or subjected to modifications 5 4 21 Supplier developed military products available in a cataloque W Various military products like various calibre weapons or weapon systems reported in catalogues and technical specifications issued by the manufactures suitable to be installed on naval mounting or vehicle turrets or portable as armoured vehicle personnel equipment completion 5 4 22 Equipment Y The following main categories of equipment are identified a machining equipment YL b measuring test equipment YC c lifting equipment YS d logistic equipment YM All equipment shall conform to applicable European Directive Waivers shall be notified to OTO MELARA and receive written approval 5 4 22 1 Machining equipment YL These are devices fixtures that allow the execution of one or more mechanical machining by locking the work piece in position and orientating it as required they may be equipped with clamping elements that are controlled mechanically hydraulically or pneumatically in which case they provide a man machine interface for control purposes 5 4 22 2 Measuring equipment YC These are devices that allo
106. h the relevant electronic medium and in details for manuals text MS Word tables MS Excel Access IPC tables image figures vectorial or as an alternative raster for spare part catalogues development data base MS Access image figures vectorial or as an alternative raster OTO MELARA Logistic Business Line shall provide the information on how to develop the documentation its contents layout and editing in the job order specifications 15 3 PENALTIES Failure to provide these documents any delays compared to the set times or incompleteness shall involve penalties that will be ruled by specific items under the Purchase orders and or Contracts RQA0001 MELARA QUALITY REQUIREMENTS a of 110 A Finmeccanica Company 5015 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A 16 ACTIVITIES DEVELOPED BY SUPPLIERS AT OTO MELARA i g Refer to subsection APPLICABILITY for instructions on how to handle these activities 16 1 GENERAL The Suppliers required to carry out activities at OTO MELARA s production lines must strictly comply with the requirements prescribed by the Purchase Orders Contracts the applicable law requirements the applicable documentation PSA0001 procedure Safety procedure for contractors from the Single Document on the Assessment of Risk from Interference DUVRI which must be obtained from OTO MELARA if not already received as an annex to the contract o
107. has been inspected and tested according to the provisions and the order requirements r Signature by the Government Surveillance in the cases provided and of the relevant sections of the Certificate of Conformity drawn up according to the contents of STANAG 4107 Certificate of Conformity in accordance with Annex B of AQAP 2070 TT Note 1 The Supplier is recommended to use as standard for its Certificate of Conformity the form reported as attachment 4 or the one envisaged in AQAP 2070 which is mandatory when the Government Surveillance is applied under STANAG 4107 RQA0001 61 of 110 oTo MELARA QUALITY REQUIREMENTS a A Finmeccanica Company August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A 8 11 FILING AND CONTROL OF THE DOCUMENTS RECORDING THE SUPPLIER S ACTIVITIES Documents recording the Supplier s activities must be kept available for OTO MELARA and or its Customer for at least 10 years unless specified otherwise in the contract In case of item with criticality level 1 the relevant documentation shall remain available for at least 15 years w OTO MELARA may ask for the documentation and certification to be sent to it at no extra cost If Quality Assurance Control documents or certifications are valid for or applied to more than one product including ones of different type the Supplier may only file them among its quality records for the first item by type of product
108. he faulty part if still covered by guarantee will be sent to the Supplier at its expense The Supplier must produce a thorough Failure Analysis detailing the type of failure and the possible causes On completion of the repair work or the analysis the Supplier must return the part to OTO MELARA free of charge w 7 15 2 Spare parts included in the supply and or in stock The Supplier must provide a list agreed with the OTO MELARA Logistic Business Line drawn up to meet OTO MELARA s and the Customers needs and make spare parts available for a period of time equivalent to the estimated life of the product when not specified otherwise by laws and or sector regulations The spare parts list shall include 1 spare parts relevant to assemblies subassemblies designed by OTO MELARA Part Number Weight and dimensions Price 2 spare parts relevant to assemblies subassemblies designed by OTO MELARA derived by a logistic analysis carried out by the Supplier OTO MELARA Part Number Closest assembly NHA Description spare identifying title Code of the spare referred to type and use Criticality code of the system related to failure of the item considered Repair code if can be repaired or not Quantity for nearest assembly Spare total quantity in the system Reliability datum MTBF Expected life for wearable parts Shelf life Lot minimum deliverable quantity Dimensions length width height Weight P
109. heating Indication of pre and post heating temperatures and inter pass where applicable GAS Indication of the gases used for protection specifying the types name and chemical symbol mix percentage and flow rate l min Reference standard EN 439 Electrical features Indication of the current continuous or alternating its polarity straight or reverse voltage filler metal mode of transfer Welding technique Indication of the mode of transfer of the welding metal short arc spray arc pulsed arc dip transfer diameter of the nozzle wire free distance preliminary and inter pass cleaning method of grooving type of seam torch angle and direction and the electrode type The document must be stamped and approved by the welding technician 13 3 WELDING PROCEDURE QUALIFICATION WPAR PQR As a general approach the welding procedure qualification activities follow the rules related to the product UNI EN ISO 15614 2 standard for example has as matter the welding procedure qualification for aluminium and its alloys through the execution of representing test specimens The standard describes the specific weld qualification procedure WPS in particular test specimens form and dimension and execution conditions validity limits tests and controls are described The same execution RQA0001 85 of 110 oTo MELARA QUALITY REQUIREMENTS a A Finmeccanica Company August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELA
110. ial test prior to use and periodic verification to confirm their validity The Supplier shall maintain the list of gauges equipment instruments belonging to OTO MELARA duly updated 7 5 NON DESTRUCTIVE TESTS NDT Non Destructive Tests NDTs must be performed by personnel qualified according to UNI ISO ASTM AWS standards or according to the Suppliers internal qualification procedures approved by a level III NDT operator P These are tests performed to establish the integrity of a part or the success of a process using means of analysis that do not require the part to be sectioned or destroyed American Society for Testing Materials American Welding Society 120 121 RQA0001 41 of 110 oTo MELARA QUALITY REQUIREMENTS 2 75 August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A Note For non OTO MELARA designs the Supplier must comply with the welding specifications and the NDTs indicated by the company handling the design These documents will be referred to in the Order Purchase Agreement w 7 6 EXECUTION OF THE FAI FIRST ARTICLE INSPECTION FAI purpose is to give objective evidence that design characteristics and requirements are appropriately understood accountable verified and documented The documentation generated and submitted to OTO MELARA will be based on recordings that allow checking the full compliance of the product with the appli
111. icate by ticking 2 1 the appropriate box if itis a partial or complete delivery 2 Declaration of conformity to be signed by Supplier entitled person 8 Progressive Number in OTOMELARA order 8 Supply description 10 Supply Quantity 0 11 Packages number 12 Supply Quantity still to be delivered in respect to total quantity 13 Quantity already supplied in respect to total quantity 14 When required fill the form with the requested data indicating e g requests for concession waiver which may be issued if approved by OTO MELARA i RQA0001 CS e MELARA QUALITY REQUIREMENTS ae 04 A Finmeccanica Company August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A 18 4 2 Form example CERTIFICATO DI CONFORMITA Pag 1 di pagine Acquirente 2 Riferimento data dell Ordine e successive varianti Contratto Governativo n 4 Trasmesso a 6a Materiale Spedito a Destinatario 5 Ragione sociale del Fornitore che emette il Certificato b Numero data del documento di trasporto ed indirizzo dell Unit produttiva Spedizione Parziale Spedizione Finale 7 Si certifica che a meno delle deroghe concessioni riportate nella casella 14 la totalita delle forniture sotto elencate o dei servizi sotto elencati su tutti gli aspetti conforme alla e specifica specifiche al ai disegno i ed al relativo ordine sopra riportato e che le forniture sono state ispez
112. ided that the compliance to the requirements under subsection LOGISTIC PACKING REQUIREMENTS are met b The connectors of the equipment and cables must be protected with plugs provided or if not provided by plastic plugs of a suitable size No alternative solutions are allowed C The materials sensitive to electrostatic discharge must be kept and delivered in suitably identified protective packaging in accordance with the provisions of the OTO MELARA s Manufacturing Procedure PF 040 22 d Inertial materials gyroscopic platforms and gyroscopes must be kept and delivered in suitably identified protective packages equipped with suitable shock detectors 9 4 6 Generic elastomers These are the materials used totally or partially as elastomers except for hose pipes a All the packages must be accompanied with an identification tag showing the polymerisation vulcanisation date materials with a limited life following the instructions of procedure OTO GO 00 b The packages used for rubber gaskets must protect the contents from the sun and ultraviolet rays and from fluids oils fuels water etc c Multiple packaging is allowed with the following limitations gt parts must have the same drawing number and polymerisation vulcanisation date gt the internal diameter must be lt 400 mm and development lt 1600 mm gt each package must not contain more than 20 pieces and weigh more than 100 kg gt Each part shall be individually pac
113. ification must be verified by the Suppliers Quality function that shall record the results of this check together with all the test results w 14 2 3 5 Despatch to the site specified by OTO MELARA The material must be despatched after successful completion of the checks on the packaging marking and identification and the accompanying documents has been completed successfully This compliance shall be verified by the Supplier s Quality function that shall record the despatch together with all the test results The Supplier shall despatch the material in compliance with the order requirements after having received formal authorisation from OTO MELARA The Supplier is responsible for getting the couriers to comply with all the rules and regulations regarding ammunition as prescribed by the applicable law or the technical documentation 14 2 3 6 Test documentation and certification of the supply At the end of the acceptance test of the object covered by the order the following documents must be sent to OTO MELARA a Certificate of Conformity of the supply signed by the Quality function or the Head of the company drawn up in accordance with the form referred to in Annexe B of AQAP 2070 b copy ofthe certificates of conformity of any lot batched components C identification codes of the products materials included in the supply containing dangerous substances under the REACH Regulation and the related safety data sheets These con
114. ing must be documented If the stamp is lost this will require the withdrawal of the remaining stamps that bear the same identification for at least one year An illegible stamp must be replaced 8 7 DOCUMENTATION RELEVANT TO ITEM WITH CRITICALITY LEVEL 1 If the supply comprises components identified as safety critical in addiction to what has been envisaged the Supplier agrees to a maintain for at least 15 years from the end production date referred to the product where the component is present the orders and relevant variants all documentation dealing with safety characteristics test performed modification required to the product or to the manufacturing process manufacturing defects test results All the above also in case of ceasing the supply to OTO MELARA b deliver for each supply documents certifying material characteristics and controls relevant to the envisaged safety characteristics c point out promptly to OTO MELARA Quality any possible safety characteristic failure d point out to OTO MELARA Material Management change proposals relevant to items components materials or manufacturing or control process e record on manufactured products the Supplier name or identification code the date or code of manufacturing Manufacturing date shall indicate manufacturing month and year or the batch if several batches are produced monthly f be available for OTO MELARA inspections related to organisation effectiveness for what relates
115. ionate e provate in accordo con le condizioni ed 1 requisiti dell ordine Data Firma della persona abilitata Fornitore Nome e titolo timbro 8 9 10 11 12 13 Voce dell Ordine Denominazione Numero di Disegno Part Quantit Numero Quantit Quantit Number comprensivo di indice di revisione della Imballaggio ancora da Montante numero di serie o lotto fornitura consegnare Spedita 14 Note Piano della Qualit numero di protocollo rev Piano di Fabbricazione e Controllo numero di protocollo rev Elenco Deroghe Concessioni Eventuali parti mancanti rispetto la configurazione del prodotto finito Elenco certificazioni allegate FAI First Article Inspection Report numero di protocollo relativa data Continuare la lista su pagine separate se necessario richiamando come riferimento il numero di Certificato di Conformita Rif Rete Aziendale Proc Uff RQA0001 04 Allegato 4 CoC MSW 2010 RQA0001 110 of 110 MELARA QUALITY REQUIREMENTS d A Finmeccanica Company August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A 18 5 ATTACHMENT 5 WELDING PROCEDURE SPECIFICATION FORM WPS N PROC N MANUFACTURER S WELDING PROCEDURE SPECIFICATION WPS PROCEDURA DI SALDATURA Supp N WPAR disupp_____ Date Data Joint Design and Welding Sequences Schizzo del Giunto e Sequenze di Saldatura Welding Process Processo di Saldatura Type Tipo
116. ipes made of carbon steel stainless steel and light alloys 5 4 7 Castings G Unfinished products for specific applications obtained by casting 5 4 8 Forged and moulded parts H Unfinished products for specific applications obtained by forging and moulding 5 4 9 Electrical control panels consoles l Assemblies able to develop specific functions autonomously or through interconnections with other assemblies 5 4 10 Nuts bolts and screws L Mechanical linking fastening elements capable of performing structural functions 5 4 11 Welding material M Materials used in welding processes wire coated electrodes gas fluxes etc 5 4 12 Complete assemblies N Assemblies of components or equipment designed to perform set functions in a plant or system they usually provide set performances according to the Suppliers or OTO MELARA s design 5 4 13 Electrical and electronic components O Loose commercial components or Approved Source or QPL assemblies or electronic boards Harnesses 5 4 14 Optical and electro optical components and assemblies P Components or assemblies that perform the function of panoramic vision reconnaissance or aiming the weapon in the visible or infrared spectrum whether or not equipped with stabilisation of the line of sight and coupled with laser pulse emitters for range finding They are generally made by specialised firms to specifications approved by OTO MELARA 5 4 15 Software
117. ision index or issue date subsequent amendments or revisions to these publications apply only if specifically introduced in this procedure as update or revision For publications without a revision index or without issue date the latest available revision of the same applies Note 1 NATO standards can be looked up on the following website http www nato int docu standard htm Their structure follow that of ISO 9001 2008 which is subdivided into 3 separate standards AQAP 2110 2120 2130 and an additional one AQAP 2131 limited to firms performing simple activities that can be verified by means of final inspections There is a dedicated standard for software AQAP 2210 Note 2 The status of UNI EN ISO standards can be obtained online from http www uni com http www iso ch Note 3 MIL standards can be obtained online from http assist daps dla mil quicksearch http www fas org man dod 101 sys index html RQA0001 13 of 110 oTo MELARA QUALITY REQUIREMENTS a A Finmeccanica Company August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A 3 1 SUPPLIERS CLASSIFICATION IN SUPPLIERS LIST Suppliers to get an order shall be registered in OTO MELARA Suppliers List and classified according to their characteristics and capabilities It is fundamental that OTO MELARA s questionnaires are properly filled and returned to have all information necessary for proper recording in the Suppliers List and to issue a Purchase Or
118. ity only at La Spezia plant 7 QPM Quality Program Manager EN RQA0001 18 of 110 OTO MELARFAI QUALITY REQUIREMENTS 04 A Finmeccanica Company August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A TABLE 4 DOCUMENTS ISSUED BY THE SUPPLIER THAT IMPACTS ON LOGISTICS DEPT CONTINUES FROM TABLE 3 24 Documentation attesting the For info For action For info conformity of products not directly sent to MELARA but to another Supplier for product completion 25 Non conformity report for For info For action For info subcontracted or on loan Reply within 3 materials supplied by OTO working days of MELARA e g equipment the report expired materials 26 Spare parts list and documents related to the product 27 Technical charts for non For action For info metallic materials and chemicals delivered with the first supply 29 Shipment document For action For info For info and to make i visible to the other departments 30 Documentation envisaged for For action For info For info carrying out activities in OTO MELARA facilities 31 Documentation envisaged for For info For action carrying out activities in shipyards for setting to work and service to OTO MELARA Customer 32 Invoice For action Paid according to the result of the Inward Quality Inspection Note OTO MELARA departments that receive document for action will distribute them to the other department in
119. ivities and documents to be developed in connection with the above stages see Table of paragraph 11 10 The activity and document modulation criteria are established in relation to the software awareness level attributed by OTO MELARA for each supply in the technical specification covering software development activities or in the purchase order contract see Table of paragraph 11 10 There are three awareness levels determined by criticality levels are three 1 2 and 3 and they are defined on the basis of the following a safety impact Integration complexity development architecture availability level well proven design specific critical characteristics ex for operation and mission maintainability throughout the life cycle of the product other important contract requirements If the purchase order contract or the specification referred to does not define the above level the Supplier must apply level 2 The Supplier must send the Project Plan with the contents shown in Table ll to OTO MELARA for approval within 60 calendar days of the date shown on the NTP Notice to Proceed or in the letter of assignment both intended as contract documents or in the purchase order contract When OTO MELARA formalises its relationship with the Supplier by means of several documents issued on successive dates and therefore increasingly complete the Supplier must refer to the date of the first such document The Project Plan must includ
120. ivity referring to the main parameters base material filler metal shielding gas and so on w All welding activities must be supervised by personnel with the appropriate skill EWF professional figure whose know how about welding encompasses basic welding principles and procedure his responsibility comprises co ordinate activities for qualifying the procedures WPAR PQR before production in accordance with the relevant section of UNI EN ISO 15614 unless otherwise specified in the order or contract compile the WPS relevant to the envisaged typical joints co ordinate qualification of the welders involved in production co ordinate and or execute the test on production welds Welder and process qualification WPAR PQR is a document that is issued by a recognised or examiner body to the welder and to the organisation which have passed specific welding tests 13 1 1 General requirements for control activities Welded joints shall be free from unacceptable defects that can be prejudicial for the intended use Acceptability levels shall conform to applicable standards After welding the acceptability shall be verified in accordance with applicable criteria unless otherwise defined in the order or drawing through visual examination as per UNI EN 970 flaws evaluation in accordance with UNI EN ISO 5817 class Medio C for steel arc welding UNI EN ISO 10042 class Medio C for aluminium and its alloys arc we
121. ked 9 4 7 Trade materials Standard packaging is allowed provided that the requirements under subsection LOGISTIC PACKING REQUIREMENTS are met i RQA0001 65 of 110 oTo MELARA QUALITY REQUIREMENTS A Finmeccanica Company August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A 9 4 8 Ferrous end products without any protective surface treatment Besides meeting the requirements under subsections APPLICABILITY LOGISTIC PACKING REQUIREMENTS GENERAL REQUIREMENTS for these materials a protective treatment with Tectyl 900 Valvoline Oil Company must be provided in compliance with General Requirements w 9 4 9 Material despatched directly to an other Supplier of OTO MELARA If the Supplier is requested to send the product to another OTO MELARA s Supplier it shall keep to the above packing and shipping instructions for the product which shall be identified as accepted and shall send OTO MELARA Materials Management and Quality the following documents a a copy of the shipping document b the Certification required that shall not be sent to OTO MELARA s Supplier c the Certificate of Conformity signed by the Quality Manager or his her authorised representative a copy must also be sent to the Supplier of the following activities together with the materials products If any of the above documents is missing this will prevent OTO MELARA from performing the inward quality control and thus paying the invoices
122. l apply what reported for items of safety criticality level 2 except for the case where it s evident the need to refer to safety criticality level 1 5 1 2 Commodity classification in terms of quality requirements The letter identifying the commodity classification in terms of quality requirements is shown on the parts list for visibility by the departments that must be informed TABLE 6 COMMODITY CLASSIFICATION Non metallc Indefinite materals A Functionally important non metallic materials 1 B Plant systems 1 1 1 1 1 4D Manufacturing using subcontracted materials CE Metallic indefinite materials and unfinished products F Castings 66 Forged and moulded parts 1 Electrical control panels consoles 1 1 Welding material Complete assemblies NN Electrical and electronic components 1 1 0O 0 2 Optical and electro optical components and assemblies P Software O Q Ammunition RR Hydraulic or pneumatic components 1 S Activities performed by Suppliers at the OTO MELARA plant internal T Services rendered by Suppliers at the Customer sfacility external Catalogue commercial parts mechanical _ V Supplier developed military products available a catalogue WW Equipment 1 Y TABLE 5 CRITICALITY LEVELS nA Code 0001 Page 21 of 110 QUALITY REQUIREMENTS Rey 04
123. l changes Configuration elements elements kept under configuration control Software Source codes documents configuration application development system work product Requests for changes This defines the proposal of change generally in the specification of the system software requirements the source can deviate from either OTO MELARA or the Supplier X application development system Change control This folows the requests for a documents change until its completion with or without actual changes with all the related information Maintenance This defines the rules priorities plan strategy events and responsibilities for changes to the installed system software components 4 Customer service User manuals diagnostics Y documentation maintenance A Code RQA0001 Page 80 of 110 MELARA QUALITY REQUIREMENTS Rev 04 A Finmeccanica Company Date August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A TABLE lll WORK PRODUCTS WP TO SUPPLY System Software Life Cycle Model Coding Standard AAA ie _ Design Plan x X x x Minutes of the meeting general reviews reviews Analysis result general 112 14 112 14 15 risk 15 risk NECEM IL Project Risk Management dia ai acid ATA strategy 7a System Software sonora Plan _ Review documents general Stages Stages _ Stages Stag
124. lded joints through Non Destructive Tests as per applicable UNI EN for the type of control as provided for by the MCP Manufacturing and Control Plan dimensional examination of welding as per UNI EN 22553 ISO 2553 Control activity evidences shall be recorded on suitable forms that must include qualified personnel names Non destructive testing personnel shall be qualified in accordance with UNI EN 473 The outcome of inspections and tests after welding shall be recorded in the dedicated fields of MCP for the internal or external cognizant authorities 13 2 WELDING PROCEDURE SPECIFICATION WPS To give instruction to the welder the organisation shall use Welding Procedure opecification WPS arranging them in the workshop at the workstations For accomplishment it can use specific instructions work cycles that include all necessary elements for carrying out correctly the welding activity These instructions shall be prepared on the basis of an already qualified WPS Welds shall not be subject to grinding if not otherwise indicated on the drawings The WPS contents shall be in accordance with specific basic requirements related to the parameters used for the weld joint execution The producer can use as a model the form reported as attachment 5 The WPS which shall undergo a verification by OTO MELARA Quality shall contain the following information as applicable General indications e WPS number i RQA0001 84 of 110 7
125. lier shall provide a list of authorised testers by qualification and perform the tests specified according to the procedures supplied by OTO MELARA or processed by the Supplier according to the technical documentation specified on the order Objective evidence of these activities must be presented Unless specified otherwise on the OTO MELARA s order the inward intermediate and final test control records shall be filed and kept for at least 10 years from when the supply has been completed 14 1 4 3 Documentation for the certification of the supply The following documentation must accompany the material when delivered Original Certificate of Conformity of the supply Any other certification specified on the order identification codes of the products materials included in the supply containing dangerous substances under the REACH Regulation and the related safety data sheets If the certification specified for the various cases is not attached to the shipping list the supply will not be accepted and returned to the Supplier at its own expense 14 1 4 4 Despatch The material can be despatched only after successful completion of the checks on the packing identification and accompanying documentation This conformity must be verified by the Supplier who must record it together with all the other tests RQA0001 MELARA QUALITY REQUIREMENTS of 110 A Finmeccanica Company 5015 QUALITY REQUIREMENTS FOR SUPPLIES TO
126. llingness to perform tests inspections agreed manufacturing activities For Quality aspects DEPT CONTINUES FROM TABLE 2 Documents issued by the OTO MELARA departments involved in document despatch Supplier Assurance QS 13 Request for modification to the For action for OTO MELARA drawings lists despatch to For technical department and aspects and Configuration 15 Project Plan both HW and SW For competence For action Order receipt and all planned documentation For Quality For technical aspects management For technical management For info For action and coordination For action with notice of at least 10 working days Procurement Materials Quality Quality i Management Materials Design dept Incoming Inspection STQ used modifications can be For info Design management Control within 60 calendar days from Project development monitoring DEN For action 22 Certificate of Conformity For action to be Supplies test certificates and controlled other documentation required to together with be delivered together with the materials supply products 23 Analysis of non conformities For action For info reported by OTO MELARA form attached to Non Conformity Report for materials products under warranty Must be returned together with the repaired reworked replaced materials STQ Technical Services of Qual
127. ment System level related to items criticality level RQA0001 10 of 110 oTo MELARA QUALITY REQUIREMENTS a A Finmeccanica Company August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A Chapter 6 and relevant tables detailed instructions pertaining to activities ad operative documentation to be related to the supply and its safety criticality level Chapter 18 explicative attachments w 2 APPLICABILITY This document applies to all supplies to OTO MELARA and in particular to all OTO MELARA designed products or coded as such products designed and developed against OTO MELARA requirements catalogue products services and technical consulting For products licensed to OTO MELARA its applicability when cited in the order is limited to general aspects Specific requirements will be integrated in the order itself This document should be considered an integral part of each OTO MELARA Purchase Order Contract when referred to therein When the Supplier accepts the Order Contract it accepts the requirements and the contract terms and conditions guarantees to OTO MELARA to have a company organization and manufacturing facilities suitable to meet the expressed requirements of Quality Assurance and Control agrees to develop the activities and to supply the required documentation in accordance with the set requirements undertakes to give prior notice of any change of the manufacturing facilitie
128. nd the Supplier the revised technical documentation with indication of introduction point The Supplier shall update the dossier of contractual requisites record the introduction point agreed and the physical introduction of the modification see example at attachment 2 Actions taken by the Supplier in the absence of official OTO MELARA documentation will not be acknowledged and the product will be rejected and all resulting costs charged to the Supplier w 8 3 2 Products designed by the Supplier to OTO MELARA specifications In agreement with OTO MELARA see the design section herein entitled PROVISIONS TO ADOPT FOR DEVELOPING THE DESIGN IN COMPLIANCE WITH OTO MELARA REQUIREMENTS the Supplier may define a frozen design configuration Baseline and send OTO MELARA a list of technical documents applying to that part of the design From this moment on all design modifications must be handled in accordance with the subsection entitled Products made by the Supplier based on technical documentation supplied by OTO MELARA OTO MELARA will inform the Supplier of the modification coding method to allow introduction and configuration of the modification 8 4 QUALITY PLAN The Quality Plan for the format and content of which it is recommended to make reference to the ISO 10005 and AQAP 2105 standards AER Q 140 in the case of supplies under the AER Q standard is the document in which the Supplier describes the organisation the o
129. noticed by the Customer shall be duly documented In case of product covered by warranty the record shall be done on the Defect Technical Analysis form attached to Non Conformity Report for Supplied items the form shall be filled with the required indications a defect cause an or observations of the Non Conformity Report of OTO MELARA b corrective and containment actions to prevent the recurrence of the non conformity found RQA0001 49 of 110 oTo MELARA QUALITY REQUIREMENTS a A Finmeccanica Company August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A Rework repair operations must be erformed followin the initial manufacturing control cycle applied during production of the product in question and the Quality Requirements in the original order must be applied When the non conformity can be resolved by means of Standardised Repair Procedures they must be officially approved by OTO MELARA Note In the aeronautical field the Non conformities reported must be treated as a Customer complaint OTO MELARA expects immediate attention by the Supplier w For defects faults that occur on the products after delivery the Supplier must ensure that all components found to be defective are subject to a detailed process of investigation on the causes of the failure found where the Product has not been returned the Supplier must confirm that the drawings the work cycles the work orders etc have been
130. nt Note 2 In the case of Aeronautical products the ISO 9001 Quality System Level is replaced with EN AS JISQ 9100 AQAP Quality System Level is replaced with the corresponding AER Q TABLE 10 INSTRUCTIONS FOR COMPONENTS OF OPTICAL AND ELECTRO OPTICAL ASSEMBLIES DESIGNED BY THE SUPPLIER ISO 9001 1509007 7150 90017 See also paragraph PROVISIONS ADOPT FOR DEVELOPING THE DESIGN IN COMPLIANCE WITH OTO MELARA REQUIREMENTS and Table 5 Note In the case of Aeronautical products the ISO 9001 Quality System Level is replaced with EN AS JISQ 9100 AQAP Quality System Level is replaced with the corresponding AER Q TABLE 11 INSTRUCTIONS FOR SOFTWARE PARAGRAPH SOFTWARE FOR 50 9001 AZIZ ei AAA 7 AQAP 2110 AQAP 2210 AQAP 2110 AQAP 2210 Note In the case of Aeronautical EMT the ISO 9001 s System Level is replaced with EN AS JISQ 9100 AQAP Quality System Level is replaced with the corresponding AER Q 9 QP Quality Plan inclusive of Design Development Plan can contain the Configuration Management Plan Configuration Management Plan i COC Certificate of Conformity Acceptance Test Procedure and relevant Test Report 419 Technical Specification LS Documentation for Logistic Support Use and maintenance Manual Illustrated Parts list li t i Validation of design and development QSL Quality System Level to be applied in case of software development also AQAP
131. nts proving the features of the material and tests regarding all the prescribed safety features c report promptly to OTO MELARA Quality any anomalies found as regards the safety features d report to OTO MELARA Design Department any proposed changes to parts and or components materials and work and control processes e show on the component produced its name or identification code and the date or code of manufacture The date of production must show the month and year of construction or the production lot if there is more than one lot per month f allow OTO MELARA personnel to verify the efficiency of its organisation in relation to the safety products g transfer these OTO MELARA requirements officially to its Sub Suppliers h provide OTO MELARA with full documentation on OTO MELARA safety components should the Supplier cease its activity 11 5 DESIGN PART LIST BASELINE The Supplier must prepare and consign to OTO MELARA a Part List covering the supply structured according to father son hierarchical logic in tree form down to an elementary component level The part s tree must be provided on paper and a computer file Microsoft Excel unless specified otherwise on the order and must contain at least the following information for each part Identification of the hierarchical level part code description revision associated document code quantity at an assembly level This Part List must be issued by the Supplier for the fi
132. nts to be agreed on with OTO MELARA or safety analysis format and contents to be agreed on with OTO MELARA d Preventive and corrective maintenance analysis format and contents to be agreed on with OTO MELARA Logistics Business Line e List of recommended spare parts under the warranty to be determined in accordance with RAMS evaluations and OTO MELARA Logistics Business Line with an indication of the unit prices and the associated logistic data ad defined per section Spare parts included the supply and or in stock and required quantities for each year of warranty f Average repair cost and time report 11 4 COMPONENTS WITH SAFETY CRITICALITY LEVEL 1 If the design and physical construction of a product with safety criticality level 1 are required the Supplier besides the provisions under subsection 10 1 c undertakes to a keep for at least 15 years from the date of end of production of the product on which the component is installed orders and their variants drawings and technical specifications design reviews all the documents proving the safety tests RQA0001 72 of 110 MELARA QUALITY REQUIREMENTS a A Finmeccanica Company August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A performed requests for changes to the product or production process reports of manufacturing defects test results This provision also applies after cessation of the supply to OTO MELARA b keep for each supply the docume
133. o MELARA QUALITY REQUIREMENTS a A Finmeccanica Company August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A w 7 7 5 1 2 Major Characteristic A characteristic other than critical that must be met to avoid failure or material reduction of usability of the unit of product for intended purpose and the performance required 7 7 5 1 3 Minor Characteristic A characteristic other than critical or major whose departure from its specification requirement is not likely to reduce materially the usability of the unit of product for its intended purpose or whose departure from established standards has little bearing on the effective use or performance required of the unit 7 1 5 2 Acceptance threshold Critical or major non conforming units will be rejected if critical or major non conforming units in a batch certified by the Supplier as conforming will be found in the sampling examination the entire batch will be rejected Furthermore OTO MELARA in case of Minor nonconforming units may return the entire supply lot to the Supplier if sample checks carried out according to the following table give negative results and charge the cost of the checks to the Supplier The following table gives a rough indication of the acceptance threshold related to lot batch size sampling control level and criticality safety level OTO MELARA has the right to issue tables dedicated to the specific supply NUMBER OF NUMBER OF CONTRO
134. ode according to a standard development cycle that shall be in accordance with what reported in the requirements specification The documents should contain at least the following information a a description of the software s functions b the architecture of the software modules c the internal structure of the software processor d alist and a description of the software data inputs outputs e requirements trace ability to the upper level These documents must be approved by OTO MELARA 12 3 SOFTWARE MODULE FUNCTION TESTS This concerns the software stages at each elementary level of the design in order to verify their correctness and compliance with the specifications The documents issued during this stage must describe to a level of depth agreed with OTO MELARA and described in the Test Plan all the procedures for the function tests that have to be performed on each module and must report the results 12 4 SOFTWARE INTEGRATION The various modules must be integrated and tested following the procedure envisaged inside the Test Plan to prove that they comply with the system requirements Dedicated Test Report shall be issued to give evidence of the related activities 12 5 SOFTWARE INTEGRATION TESTS AND VALIDATION All tests carried out shall be documented and recorded The functional and performance requirements shall be specified and the test procedures carried out on the modules shall be documented as well as the requirement com
135. of this document with proof of transmission to any Sub Suppliers g any dedicated technical documentation h documentation of non conformities found by OTO MELARA in the course of acceptance tests and inspections at the Suppliers and OTO MELARA with the analysis report and a plan of corrective preventive actions and improvements All these documents must be kept up to date by an internal focal point formally designated and presented to OTO MELARA inspectors when requested If the documentation is not made available OTO MELARA personnel may decide not to accept the product material 8 3 REQUESTS FOR MODIFICATION TO TECHNICAL DESIGN DOCUMENTATION 8 3 1 Products made by the Supplier based on technical documentation supplied by OTO MELARA The Supplier must strictly adhere to the technical documentation supplied by OTO MELARA and is entitled to propose updates design modifications in order to improve the final quality and feasibility of the product and to achieve cost reduction Proposal must be RQA0001 55 of 110 oTo MELARA QUALITY REQUIREMENTS 2 A Finmeccanica Company August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A submitted in writing to the OTO MELARA department involved see OTO MELARA Supplier documentation interface matrix OTO MELARA will inform the Supplier whether the proposal is accepted or not after internal processing by the entitled departments If the proposal is accepted OTO MELARA will se
136. oject Work Products RQAO0001 76 of 110 A Finmeccanica Company August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A 12 10 2 Description of the main Work Products and their use in system software development Various Work Product Classes can be defined for each of the above categories This classification is provided in Table I of this sub section There are various types of Work Products Each type belongs to one or more Classes w The Table Il shows a list of various Work Products and their Classes that are important for OTO MELARA buying a system software developed by a Supplier Knowing the system software purchased by means of the related Work Products enables OTO MELARA to realise that the system software is suitable for the intended use for which it was purchased and also enables to co operate with the Supplier As a minimum requirement all the Work Products listed in Table Il are made and used by the Supplier but generally only some of them are sent to the Customer depending on the degree of awareness of the system product the Customer wishes to acquire This is shown in Table Similar topics can be treated in the same document as per the Quality Plan Table III lists the requirements for supplying Work Products to OTO MELARA expressed by three level of completeness 1 2 and 3 according to criticality level which also distinguish the status of purchase of software only from p
137. on Certificate type 3 1 according to UNI EN 10204 that it is considered also applicable to non metallic Certificate of Conformity When applicable CoC Certificate of Conformity supported by Inspection Certificate type 3 1 according to UNI EN 10204 CoC Certificate of Conformity as an alternative for parts not based on OTO Melara requirements Declaration of Conformity on type 2 1 according to UNI EN 10204 4 RQA0001 0T0 MELARA QUALITY REQUIREMENTS 32 of 110 04 A Finmeccanica Company August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A TABLE 8 CONTINUED Electric panels consoles PR be mM te 2 A ado Aro Y Y maze AY bL pL LY LL LY 12 Complete assemblies 68 2 9001 52 EAM Ea Es GSES ES 9001 AQAP 2120 ISO 9001 AQAP 2130 Electrical and electronic components 70 71 22 9001 22 2120 Note In the case of Aeronautical products the ISO 9001 Quality System Level is replaced with EN AS JISQ 9100 AQAP Quality System Level is replaced with the corresponding AER Q QP Quality Plan always includes the MCP it does not apply for commodity class O for catalogue commercial components 7 MCP Manufacturing and Control Plan it does not apply for commodity class O for catalogue commercial components COC Certificate of Conformity 9 FAI First Article Inspection to be repeated in the event of important manufacturing p
138. ontrol and adequate to the envisaged treatment e furnaces with their relevant qualified temperature ranges thermal uniformity the working zones Pyrometry type and atmosphere control e quenching systems and their control e equipment hardness machines testing devices etc OTO MELARA Quality will establish inspections for Supplier qualification for that purpose specific check list for evaluation of Supplier s process conformity to applicable international standards are available These check lists can be sent to Suppliers to be duly filled and sent back to OTO MELARA Quality Q SQ Suppliers dept for evaluation w 7 4 TEST AND PROCESSING INSTRUMENTS EQUIPMENT The required instruments and equipment must be handled according to current standards ISO 9001 2008 ISO 10012 or other standards if specified in the contract The serial numbers the accuracy class and the expiry date of the test instruments and equipment calibration must be recorded on documents consigned to OTO MELARA opecial cases a Gauges equipment instruments belonging to OTO MELARA except for the need to define on the Purchase Order who should carry out the periodic inspection of gauges equipment tools which may be supplied by OTO MELARA the Supplier is responsible for using them in a correct way respecting the maintenance deadlines provided and safeguarding their conservation b Suppliers gauges and positioners used these must undergo an init
139. ontrol of the materials and of the equipment supplied to them under subcontract 7 13 LIABILITY FOR SUBCONTRACTED WORK MATERIAL BELONGING TO OTO MELARA OR THE END CUSTOMER The Supplier may receive materials or equipment for subcontracted work in either of two Ways from OTO MELARA itself from OTO MELARA s Suppliers In both cases the Supplier is responsible for ensuring the products received correspond qualitatively and quantitatively to the items listed in the accompanying documents and must inform OTO MELARA of any discrepancies shortfalls or damage The Supplier must report promptly to OTO MELARA Materials Management any problems in assembling or using the product received specifying the following the name of the Supplier or OTO MELARA facility that sent the product the number of the transport document accompanying the product the quantity affected by the problem found a description of the problem found possible corrective action to be taken ooocn RQA0001 51 of 110 oTo MELARA QUALITY REQUIREMENTS 2 August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A OTO MELARA agrees to provide precise indications of what has to be done with the material within 3 working days from the report w Subcontracted material supplied by OTO MELARA must be identified as such during the storage stage and when it starts being worked it must be identified with the as
140. or Logistic Support Use and maintenance Manual Illustrated Parts list NJ Code RQA0001 a 7oTO MELARA QUALITY REQUIREMENTS Page 36 of 110 Rev 04 Finmeccanica Company Date August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A TABLE 15 INSTRUCTIONS FOR EQUIPMENT FIXTURES DESIGNED BY THE SUPPLIER 110 111 112 113 114 115 116 Y Equipment Fixtures metes a 9001 _ Bassi 9001 117 oss 9001 Bolli 9001 AQAP 2110 AQAP 2210 AQAP 2120 AQAP 2130 118 See also what is reported at the paragraph EQUIPMENT DESIGNED BY THE SUPPLIER Note 1 In the case of equipment designed by OTO MELARA in addition to the provisions of the Purchase Order and the related technical documentation the supplier shall apply what is provided for class N Note 2 In the case of Aeronautical products the ISO 9001 Quality System Level is replaced with EN AS JISQ 9100 AQAP Quality System Level is replaced with the corresponding AER Q TABLE 16 REFERENCES FOR COMMODITY CLASSES WHICH REQUIREMENTS ARE REPORTED IN DEDICATED PARAGRAPH RQA0001 y Activities performed by Suppliers at the OTO MELARA plant internal U Services rendered by Suppliers at the Customer s facility external Certificate of Conformity 111 CEDC CE Declaration of Conformity in case of equipment designed by the Supplier under its responsibility 112 TD Technical Dossier Technical Documentation in case of equipm
141. or delivered to OTO MELARA prior to execution of the related activities e BPS Brazing Procedure Specification e Procedure Qualification Record BPQR Brazing Performance Qualification Record These documents must be developed in accordance with ANSI AWS B 2 2 91 UNI EN 13134 standards In carrying out the process the Supplier must take special care over the following activities e cutting and adjustment surface cleaning application of the welding paste support and alignment of the assembly heating and fluxing of the welding metal Braze welding execution e Cleaning and removal of any welding paste residue Defects shall be evacuate in accordance with UNI EN ISO 18279 w 13 9 REQUIREMENTS FOR MECHANICAL UNWELDED CONNECTIONS RIVETS ETC All the indications specified in the drawing must be complied with Before starting production activities the list of personnel authorised to perform the process must be provided with details of the relevant duties and functions production and control activities All the equipment used must undergo periodic checks of which the Supplier must provide suitable evidence 13 10 REQUIREMENTS FOR WELDING ELECTRONIC COMPONENTS SOFT SOLDERING For the purpose of obtaining the required authorisation before starting series production the Supplier must provide OTO MELARA Quality with the documentation required to carry out the manual surface mount or wave welding process
142. oration or damage of supplies If these requirements are not complied with the materials supplied will not be accepted by OTO MELARA Quality any costs incurred for the protection of materials will be charged to the Supplier Reporting through the Non Conformity Report for Subcontracted Supplies and Debit Note by Administration Finance and Control 9 2 LOGISTIC PACKING REQUIREMENTS The materials must be packed in such a way as to preserve their integrity throughout all the logistic stages and warehousing and to facilitate handling storage and identification 9 3 GENERAL REQUIREMENTS These requirements always apply with the deviations and specific instructions shown under the subsection entitled Special Requirements 9 3 1 Individual packaging All the materials must be packaged individually as follows a Material polyethylene b Shape bubbles or foam c Packaging bag or suitable wrapping 9 3 2 Transport packing After individual packaging the material must be placed inside or on a transport container of adequate size and strength to be chosen depending on the weight and the shape of the cargo from the following types a transport packing to the Supplier s drawing b wooden crates c cardboard boxes d pallets The containers do not need to be brand new however they must not show any damage that might affect their integrity For tracking purposes it is advisable to mark them with the name of the sender Whatever the
143. patched product and compilation of the failure report e send the non conformity documentation to the relevant department Logistic Business Line w 17 9 INTRODUCTION OF MODIFICATIONS AND FIELD INTERVENTIONS Modification or variant introduction activity is normally carried out by OTO MELARA s personnel who is responsible for that in case the Supplier carries out these activities autonomously shall fill the documentation provided by OTO MELARA The Supplier is responsible for introducing the modifications and or variants required by OTO MELARA This activity must be e developed in accordance with the documentation received Change Orders Requests for Technical Modification etc received by OTO MELARA based on the attached or quoted drawings e performed using the materials received from OTO MELARA e Checked after introduction to verify its operation e reported to OTO MELARA on the summary sheet signed by the person in charge of the activity and countersigned by the Customer s representative if required The Supplier must report any major failure malfunction generally involving safety or continuity of operation to OTO MELARA by means of a document called Repair Recovery Form in which he she must describe the event when it occurred the presumed cause and all the information considered necessary to define the situation including photographs and sketches Corrective maintenance actions are performed to ensure that opera
144. perating and technical methods used and the stages in which it intends to develop the supply products in accordance with the requirements defined in the purchase contract issued by OTO MELARA and in the documentation referred to therein by the AQAP ISO regulations applicable and by its own Quality System This document issued in Italian unless otherwise provided for by the Purchase Order must be signed by the Supplier s Quality Manager and submitted to OTO MELARA Quality for verification and approval within 60 calendar days of the acceptance of the Order and prior to commencement of the work If the Supplier fails to submit the documents in time OTO MELARA is entitled to reject the supply The document also describes the methods for managing relations with OTO MELARA and lists the names of the people with specific responsibilities in the development and control of the supply For the entire duration of the supply the Quality Plan must be kept up to date and submitted to OTO MELARA from time to time for verification and approval The Quality Plan must always include the Manufacturing and Control Plan and the Configuration Management Plan if there is one The Supplier s Quality function must perform audits to verify implementation of the Quality Plan and the any other documents envisaged Manufacturing and Control Plan and the Configuration Management Plan The Quality Plan shall also give objective evidence about the risk planning including th
145. pliance matrix The Supplier shall provide at its own expense the necessary technical assistance for the integration of the RQA0001 y 74 of 110 Finmeccanica Company August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A modules in the final product and for the solution of any compatibility and interface problems with other systems subsystems components When required the Supplier shall be available to attend the joint integration test and validation activities of its modules that will be carried out at OTO MELARA premises and or at the final user w 12 6 SOFTWARE RELEASE At the end of the validation tests and before the delivery of the software the Supplier shall issue the Product Baseline which shall contain all reference and documents that identify unambiguously the final product and maintain it during OTO MELARA product life cycle The Supplier shall assure Configuration and obsolescence management for support and compatibility of its product 12 7 MAINTENANCE DURING PRODUCTION STAGE AND AFTER SALE Once released the Baseline the product enters the maintenance phase where it remains till the end of its life cycle In this stage the Supplier is responsible for change introduction The Supplier must define and submit to OTO MELARA for approval the criteria for selecting the tests to be repeated in the event of a modification including non regression tests of the performance All the tests performed m
146. plication that are consistent with the types of supplies proposed by the Supplier 150 9001 2008 Quality Management Systems Requirements SCS 150 9000 2005 Quality Management Systems Fundamentals and Vocabulary AQAP 2110Ed 3 Quality Assurance Requirements for Design Development and Production Ex AQAP 150 AQAP 2110 AQAP 2210Ed 1 NATO supplementary Software Quality Assurance Requirements to P eaaa o A 891 2070 Ediz 2 NATO Mutual Government Quality Assurance process AER Q 10 Requirements for Quality Assurance by D G A A concerning design development and production AQAP 2009 Ediz 2 NATO Guidance on the use of the AQAP 2000 series EN AS SJAC Quality Management Systems Requirements for Aviation Space and 9100 2009 Defense Organizations NDA0002 Code of Ethics of OTO MELARA S p A This document refers by references with a revision index or not or by issue date to provisions from other publications As for the references with a rev
147. pping documents showing the following details Supplier s company name OTO MELARA Purchase Order number reference and any other Variants item number of the Purchase Order OTO MELARA Code Part Number obtainable from the order serial number lot number or date of manufacture description of the component g quantity For the products subject to expiry the relevant validity date must be recorded in particular for products made of elastomers the polymerisation data shall be reported see OTO MELARA procedure OTO GO 00 The requirements specified in this subsection do not apply to catalogue products with the Supplier s own marking coding This identification must be applied outside the intermediate final transport containers A clear plastic envelope containing a copy of the shipping documents and required certifications is affixed on one of the external surfaces of the final container 9 4 SPECIAL REQUIREMENTS In the specific cases mentioned below the following special provisions shall apply 9 4 1 Small size parts to drawing a For small parts weighing less than 0 1 kg each clear polyethylene bags can be used thickness gt 0 2 mm b for small unpainted parts without deteriorating worked surfaces multiple packing in a single polyethylene bag of the bubble or foam type can be used up to a total weight of 0 5 kg 9 4 2 Blanks Except for micro castings no individual packaging is required for metal plates
148. r Manual in accordance with applicable requirements to be delivered together with the supply including information about possible residual risks i RQA0001 67 of 110 7 MELARA QUALITY REQUIREMENTS 2d A Finmeccanica Company August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A 10 3 DESIGN The Supplier shall observe the applicable Directive and give the relevant evidences for correct design approach in particular where applicable European Directive n 2006 42 CE for machines European Directive n 1997 23 CE for equipment subject to pressure European Directive n 2006 95 CE for low voltage equipment LVD European Directive n 2004 108 CE relevant to Electro magnetic Compatibility The Supplier shall remain updated on the matter 10 3 1 Technical Dossier TD The Supplier must prepare a Technical Dossier demonstrating that the equipment complies with the requirements of the specific European Directive For the Technical Dossier content the Supplier must refer to the relevant European Directive annex w 10 3 1 1 Risk analysis evaluation dossier RED The Supplier must draw up a risk evaluation dossier in compliance with the applicable regulations see as a suitable support UNI EN ISO 14121 1 2007 UNI EN ISO 12100 1 2009 and UNI EN ISO 12100 2 2009 10 3 2 User Manual UM The Supplier must issue a User and Safety Manual in one or more official European Community languages a
149. r variants e the reporting of major or recurring problems e the management of faulty products The Supplier must also provide the necessary support in the search for solutions and in discussions with the Customer and or Suppliers in order to make a correct determination of the party responsible for the failure 17 8 MANAGEMENT OF NON CONFORMITIES AND FAILURES Management of non conforming or faulty products is normally carried out by OTO MELARA s personnel who is responsible for that in case the Supplier carries out these activities autonomously it shall fill the documentation provided by OTO MELARA It is the Supplier s responsibility to e identify the non conforming product or the failure by means of an identification tag before it is placed in a dedicated area in the warehouse that is physically separate from the area set aside for spare parts e compile a product failure report on the form supplied by OTO MELARA providing the information required for a full and correct understanding of the situation found RQA0001 102 of 110 oTo MELARA QUALITY REQUIREMENTS a A Finmeccanica Company August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A e handle contacts with the OTO MELARA units and or the Suppliers for the return of the product taking care that this is accompanied by the non conformity report e send reminders to the OTO MELARA unit and or the Supplier if necessary e check the state of the repaired and or des
150. rams assembly and part drawings connected with the different design development stages g execute and record the Design Review meetings detailing the technical and interface aspects exhaustively and comprehensively h document the design verification and functional validation activities to provide proper confidence on the project giving adequate evidence in a compliance table i freeze the design or its values through appropriate documentation drawings lists and technical specifications each identified with the related revision index to determine the reference configuration baseline j process and update the design configuration through a careful analysis and application of the design modifications following freezing in accordance to what reported ay paragraph 6 3 2 k use qualified calculation programs l use qualified personnel for specific activities m ensure adequate resources to execute the needs of the project in order to respect the programmes agreed in the contract n handle any delays through effective recovery actions promptly report any lack of information or discrepancies regarding the supply received so as to prevent from being in a situation of delay which in the absence of such information will be charged by OTO MELARA to the Supplier o ensure the interface with OTO MELARA systems in the development of reports in an electronic form and promptly report to OTO MELARA any mechanical electrical electronic soft
151. re shall be provided with a CE label in a visible zone with readable and indelible inscriptions in accordance with applicable European Directive w 10 6 DECLARATION OF CE CONFORMITY It is the declaration released by the manufacturer or its agent inside European Community attesting that equipment offered for sale observes all related essential health and safety requirements concerning it That documentation containing data required by applicable Directives shall be signed by a person authorized by the manufacturer or its mandatory and sent to OTO MELARA together with the supply Names and positions inside the Supplier organisation shall be reported in full and in a readable form OTO MELARA reserves the right to ask the Supplier for the documentation attesting authorization to issue and subscribe that declaration i RQA0001 69 of 110 oTo MELARA QUALITY REQUIREMENTS a A Finmeccanica Company August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A 11 PROVISIONS TO ADOPT FOR DEVELOPING THE DESIGN IN COMPLIANCE WITH OTO MELARA REQUIREMENTS w This Chapter integrates previously defined requirements under subsection APPLICABILITY The documents to deliver to OTO MELARA are listed in Table 9 The Supplier of a design activity based on OTO MELARA requirements shall have a Quality management System in accordance with what reported at paragraph 5 according to criticality level of item or assembly to b
152. requests for deviation and or waiver Quality is also responsible for the final acceptance of delivery If the supply includes the design the monitoring will be done by OTO MELARA Design Department 7 7 5 Acceptance inspections and tests at OTO MELARA facilities otated the Supplier s responsibility for consigning conforming and already tested products unless specified otherwise in the Purchase Order OTO MELARA will perform the following inspections at its facilities on incoming goods established according to supply criticality Packing requirement conformity quantity correspondence state of the goods supplied compliance with the accompanying documentation visual and technological tests physical and chemical properties where required dimensional checks where required g function tests where required 0ococm 7 7 5 1 Non conformity A departure from a specified requirement for any characteristic and performance A classification of non conformity is given in the following 7 7 5 1 1 Critical Characteristic A critical characteristic is defined as follows characteristic that judgment and experience indicate must be met to avoid hazardous or unsafe conditions for individuals using maintaining or depending upon the product characteristic that judgment and experience indicate must be met to assure performance of the tactical function of a major item such as a ship aircraft tank RQA0001 y 45 of 110 oT
153. rked engravings a Macro graphic test to check penetration percentage of the molten zone and surface marks Tests including O Tensile strength Shear Test to check the average and maximum ultimate tensile strength Execution of at least 5 specimen if not otherwise specified The results obtained must be checked to ascertain that they match the reference tables O Cross Tension Test with execution of at least 5 specimen if not otherwise specified to verify spot dimension after peel test with reference to the core size e average ultimate tensile strength The values obtained must be compared with the reference values to check whether they fall within the acceptability range At each start of production execute at least two specimen for Peel Test to verify the core diameter envisaged in the drawing in respect to qualification data Moreover these tests must be performed whenever e the electrodes are replaced e the welding machine set up conditions have changed e any element is replaced 13 8 GENERAL BRAZE WELDING REQUIREMENTS Braze welding must be developed in such a way as to make joints from materials of the same or of a different nature that are resistant to corrosion and vibration The Supplier must guarantee the use of qualified processes and operators i RQA0001 88 of 110 MELARA QUALITY REQUIREMENTS 21 Finmeccanica Company August 2012 In particular the following documents must be produced
154. rocess or Suppliers change it is mandatory for supplies of aeronautical products it does not apply for commodity class O for catalogue commercial components IT Type Tests Qualification Tests 91 WPS Welding Procedure Specification SPC Applied Special Process certificate HTC Heat Treatment Certificate can consist of certificate relevant to the obtained mechanical characteristics such as hardness resilience tensile strength furnace according to characteristics criticality level STC Surface Treatment Certificate NDT Non Destructive Tests ATP Acceptance Test Procedure and relevant Test Report POR Procedure Qualification Record BT Ballistic Test when required DCC Dimensional Characteristics Certificate 97 QSL Quality System Level ni When assemblies are designed by the Supplier see also Table 9 di For mechanical structures refer to Class C requirements Electric and electronic components e In case components are from stock and when Supplier is a dealer parts shall not have been manufactured more than 5 years before the delivery date unless otherwise indicated in the order e In case the Supplier is the Producer parts shall not have been manufactured more than 5 years before the delivery date and it is required a test report not older than one year e n case of obsolescence it is required that the status is declared together with the information about the date of production cessation e broker
155. roved following formal Request for Deviation or Waiver This document is consigned in a complete form to the Supplier which must look up in it the requirements referring to the supply commissioned in accordance with the elements in the technical documentation and in the order It should be noted that the implementation of these requirements is implicit in the acceptance of the order The Supplier must also be sure to have this document is the latest revision Updated revision can be downloaded from http www otomelara it If the Supplier uses Sub Suppliers accepted by OTO MELARA it must inform them of these requirements and include them in its purchase orders The requirements contained herein shall apply to each Sub Supplier according to the type of goods or services supplied 1 1 GUIDE TO RQA0001 CONSULTATION To ease the consultation of the document the essential paragraphs for a correct interpretation are reported in the following Paragraph 2 1 correlation table between type of supply and requirements contained in the document 0001 Paragraph 4 1 interface matrix OTO MELARA and Supplier Paragraph 5 1 and Table 5 classification of the Criticality Level Paragraph 5 1 2 and Table 6 commodity classification in terms of quality requirements and interpretation of the drawing legend Paragraph 5 2 Supply Quality System level associated with the criticality level Paragraph 5 3 and Table 7 Supplier Quality manage
156. rst time within 60 days of the formal or informal supply agreement and must be updated every two months up until completion of the supply unless specified otherwise by OTO MELARA w 11 6 SERIES PRODUCTION All the requirements set out in this document apply in this case The Quality Plan and the Configuration Management Plan will be updated and finalised at this stage in the product s life cycle 11 7 DRAFTING For activities that cannot be strictly defined as design e drafting of parts intended to become components of an assembly designed by OTO MELARA new drafting of assemblies or parts for updating graphic or standards related to tolerance indication and representation convention three dimensions modelling solid modelling from old drawing that hai to solid models or drawings identified as OTO MELARA proprietary the supplier shall follow the OTO MELARA rules for filling the drawing legend The Supplier shall also check the correspondence and consistency of the assemblies and parts designed with the original drawings in case of redesigning or with the assembly from which the new drawings are made in case of redesigning special components or three dimensional modelling i RQA0001 73 of 110 MELARA QUALITY REQUIREMENTS 2 1 August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A 12 SOFTWARE g If the supply includes so
157. rt which can be supplemented with the Failure Analysis form for materials products under warranty b The original Failure Analysis form completed in full to certify the rework repair detailing any corrective actions performed to prevent any recurrence of the non conformity c the original test reports for the tests and inspections performed and their findings d other certificates referred to in the specific repair rework order if issued e certificates required by OTO MELARA specifications for special processes when applied f the rework repair certificate If the certificates listed are not attached to the packing list the supply may not be accepted in which case it will be returned and the costs will be charged to the Supplier i RQA0001 50 of 110 7 MELARA QUALITY REQUIREMENTS 27 August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A The Supplier must procure at its own expense any subassemblies components and materials required for the rework repair activities and to preserve the documentation for at least 10 years from the date of delivery unless otherwise indicated in the purchase order w N B The rework repair certificate must quote all the references of the order and the Non Conformity Report for Subcontracted Supplies and show at least the following declaration of conformity It is hereby certified that the goods supplied have been re
158. s OTO MELARA requires 7Cpo oococn PROCESS QUALIFICATION CERTIFICATION PROCESS SPECIFICATION RQA0001 39 of 110 oTo MELARA QUALITY REQUIREMENTS a A Finmeccanica Company August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A 7 3 1 Process qualification Certification For qualification or certification of a procedure by a third recognized body or by a company which quality standards are known and recognized by OTO MELARA is meant the ensemble of activities necessary to demonstrate that an operational procedure can cover those requirements reported in clearly identified international standards such as UNI EN ISO DIN SAE AMS ASTM etc Qualification activity can be carried out by OTO MELARA or by trustworthy Agencies The Supplier shall attach evidences of qualification or certification to MCP Manufacturing and Control Plan when required The Supplier must send this documentation to OTO MELARA prior to consignment of the first lot of the supply w 7 3 2 Process specification It is a document that demonstrates that Suppliers organization has absorbed the international standard related to that process or if the process is proprietary all technical aspects are clearly focused by issuing an operational procedure containing parameters technical requirements methods for process control to reach product quality requirements That document shall be approved by OTO MELARA Quality and made promptly
159. s chart for the work by means of stamps that can be related to the operators 16 4 OTO MELARA S CONTROL ON THE SUPPLY OTO MELARA must inform the Supplier with due notice of the activities it wishes to attend The Supplier must call OTO MELARA Quality for a meeting at least one day in advance It should be noted that the product must be ready available for performing the set control activities at the time of notification to OTO MELARA Quality otherwise OTO MELARA will charge the Supplier any costs due to inactivity of its personnel due to unavailability of the product The Supplier must present the product to the test by OTO MELARA after having developed the verifications required If any non conformity is found OTO MELARA personnel is required to issue the relevant Non Conformity Report for subcontracted supplies and the Supplier must take the necessary steps for its solution Y RQA0001 J QUALITY REQUIREMENTS ii on TAD O0T0 MELARA August 2012 A Finmeccanica Company QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A OTO MELARA and its Customers or Representatives can perform Audits on the Supplier s Quality System and the execution of the activities The Supplier must take the necessary corrective actions within the set times and according to set methods i RQA0001 99 of 110 7 oto MELARA QUALITY REQUIREMENTS 2d A Finmeccanica Company August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A 17 ACTIVITIES
160. s part of the Quality Plan containing the documents to draw up and the activities associated with the design and development planning GANTT diagram in accordance with AQAP 2110 ISO 9001 2008 and AQAP 2210 requirements in case of Software development and OTO MELARA s requirements detailed at a macro activity level to ensure an effective project management EN AS SJAC 9100 2009 for aeronautical supplies the Design Reviews carried out both internally and jointly with OTO MELARA mandatory for Requirement Examination and after performing the type tests the strategy of the logistic project structure agreed jointly with OTO MELARA the mode of coding the technical documentation and part number the project verification and validation the configuration management in accordance with the requirements under AQAP 2110 and STANAG 4159 identification and management of COTS HW SW Commercial Off The Shelf components and modified COTS used in the design with a description of any obsolescence management strategies to gurantee the support and compatibility of its products RQA0001 70 of 110 oTo MELARA QUALITY REQUIREMENTS a A Finmeccanica Company August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A e subdivide the development stages of the assigned design logically and sequentially conceptual final and executive design f process the required technical documentation specifications functional diag
161. s site undertakes to transfer to the supply chain the applicable requirements expressed in the technical and supply documents of OTO MELARA This document integrates the Quality System of the Supplier which is responsible for implementing all the methods defined in its own quality standard the requirements of OTO MELARA s drawings technical specification and documents and applicable rules defining the performance quality and technical features of the supply The contents of this document do not affect OTO MELARA s rights and faculties in accordance with the provisions of the general purchase conditions regulating relations with Suppliers If the Supplier wishes to subcontract part of OTO MELARA s Order Contract it is necessary first to obtain OTO MELARA s Procurement consent and formal authorisation When the Supplier has received due authorisation it must Inform the Sub Supplier of the contents of this document obtain from the Sub Supplier the types of documents that apply to the supply as and when established below and send them to OTO MELARA obtain access to the Sub Supplier s offices production units and documentation for OTO MELARA and its Customer for the purposes of performing audits and attending tests and inspections give prior notice to OTO MELARA about any possible change of subsuppliers In all case OTO MELARA will consider the Supplier as the assignee of the order contract and the only one responsible for compliance to
162. safety products g make sub Suppliers officially informed about OTO MELARA s present quality requirements h make available to OTO MELARA all documents related to safety components in case of ceasing activity For what relates to products developed by the Supplier refer to PROVISIONS TO ADOPT FOR DEVELOPING THE DESIGN IN COMPLIANCE WITH OTO MELARA REQUIREMENTS 8 8 TECHNICAL CHARTS FOR NON METALLIC MATERIALS AND CHEMICALS The technical charts show the specifications of non metallic materials and chemicals used in the supply The list of substances contained in the chart must cover at least the following a painting products paints solvents diluents catalysers fillers etc b cleaning products soaps acids alkalis detergents etc i RQA0001 59 of 110 MELARA QUALITY REQUIREMENTS 25 August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A w c adhesives and sealants adhesives putties sealants adhesion enhancers etc d lubricants oil grease cleaners e welding materials electrodes welding wires deoxidizing pastes sealing compounds insulation compounds anti adhesives etc f composite materials g resins of various types h thermal and acoustic insulation fire retardant and self extinguishing materials etc i special metal plates j technical gases k grinding products metal or non metal sand blasting shot and cut wire fl
163. shall provide a certificate of conformance of the whole supply to which a copy of the certification originally issued by the manufacturer shall be attached When the products are designed by the Supplier and their are not available in a catalogue see also Table 9 I RQA0001 MELARA QUALITY REQUIREMENTS 04 A Finmeccanica Company August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A TABLE 8 CONTINUED 72 73 74 75 76 T7 78 79 80 81 82 83 OI ISO 9001 v gt Li 85 2110 2210 5 2 20 ISO 9001 2110 2210 20 ISO 9001 2131 Hydraulic and pneumatic lb dd EA EA PS ISO 9001 AQAP 2120 ISO 9001 AQAP 2130 AQAP 2131 Catalogue a MS I Note In the case of Aeronautical products the ISO 9001 Quality System Level is replaced with EN AS JISQ 9100 AQAP Quality System Level is replaced with the corresponding AER Q 2QP Quality Plan always includes the MCP it does not apply for commodity class S for catalogue commercial components MCP Manufacturing and Control Plan it does not apply for commodity class S for catalogue commercial components COC Certificate of Conformity BFAI First Article Inspection to be repeated in the event of important manufacturing process or Suppliers change it is mandatory for supplies of aeronautical products it does not apply for commodity class S for catalogue commercial componen
164. sociated withdrawal order from the store The same identification shall be maintained if the material is dispatched to Sub Suppliers OTO MELARA reserves the right to apply a penalty if 1 the Supplier does not inform it promptly of any assembly or processing problems connected with the product delivered 2 The Supplier does not promptly report damage or quantity discrepancies between the product delivered and the delivery note In case 2 Administration Finance and Control department shall charge the Supplier the costs of the hours spent performing the repair or reworking activities and of the subsequent inspections 7 14 ACCESS TO THE PREMISES AND DOCUMENTATION OF OTO MELARA S SUPPLIERS AND SUBSUPPLIERS See also Inspections and tests at the Supplier s or its Sub Suppliers OTO MELARA its Customer and their designated representatives will be entitled to carry out at the Suppliers main facility and operating units all the tests and inspections considered necessary to ascertain whether the supply and documentation comply with contract conditions and to perform audits of the system and or operating process The Supplier and its Sub Suppliers must provide OTO MELARA the Customer and their representatives the structures and personnel necessary to carry out the tests and inspections 7 15 SPARE PARTS 7 15 1 Spare parts for technical support to validation tests The Supplier must guarantee the availability of the spare parts req
165. solution adopted if the pack exceeds the maximum weight of 20 kg it must be provided with the suitable interface wooden supporting pallets or the like to allow transport using a fork lift truck The material must not project from the external shape of the container which in turn must be free of any nails chips or anything else that may cause harm to operators or jeopardize their safety Moreover inside on the transport container the material must be held in place using special devices that prevent the load from moving without damaging it Such devices must be chosen according to the weight and shape of the load and these can be RQA0001 63 of 110 oTo MELARA QUALITY REQUIREMENTS a A Finmeccanica Company August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A a supporting saddles b rubber foam plastic material templates c polystyrene foam or particles d straps flexible films w If a single final transport container is used to transport different materials it is necessary to provide as many appropriate intermediate containers as the types of materials loaded in compliance with the requirements specified above Moreover if the supply includes a kit made of partially pre assembled parts an individual transport container must be provided for each kit 9 3 3 Identification When delivered to OTO MELARA all the materials must be properly identified with the markings stampings labels tags and shi
166. ssuming the responsibility to this end it must insert in the instruction manual the words Original instructions with a copy in Italian if it does not already exist this translation must bear the words Translation of the original instructions In general the User Manual covers also the following installation assembly prearrangement for the installation setting to work operation maintenance and inspection plan list of risks that cannot be eliminated at a design stage with an indication of personal protection equipment technical data weight and dimensions spare parts interfaces mechanical electrical hydraulic pneumatic TIT Qo 020090p 10 3 3 Special Processes For execution of Special processes including welded joints used for assembling the various parts of the equipment refer to the provisions of the subsections entitled SPECIAL AND OR CRITICAL PROCESSES and NON DESTRUCTIVE TESTS NDT and to applicable provisions of law 10 4 TESTING The Supplier must provide evidence of having performed validation and testing of the equipment fixture with the public agency entitled to issue the related certificate all the relevant documents shall be provided to OTO MELARA together with the equipment fixture supplied RQA0001 68 of 110 oTo MELARA QUALITY REQUIREMENTS a A Finmeccanica Company August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A 10 5 CE LABEL AND MARKING The equipment fixtu
167. system software from external sources sub Suppliers This defines the architecture performance characteristics and the quality of the system software to develop or purchase on the basis of OTO MELARA requirements This defines the main components of the software to develop and their external internal interfaces N RQA0001 78 of 110 MELARA QUALITY REQUIREMENTS a A Finmeccanica Company August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A This defines the main software components to develop to be traced and their external system internal interfaces Test This defines the objectives criteria strategy validation techniques activities In general it applies to all levels of test validation Test Validation This defines the test objectives of a plan general defined project and the activities resources techniques the revised input and output data the test pass fail criteria General this applies to all test levels unit integration system acceptance Unit test strategy reproducible Test strategy WP 14 applied to a software component in general an executable unit Test plan WP14a applied to a Unit test plan software component in general an executable unit test Test strategy WP 14 applied to the strategy integration system intended as a progressive test components aggregation test Test plan WP14a applied to the strategy integration
168. t 24 hours in the destination environment so as to allow them to reach the correct ambient temperature i RQA0001 86 of 110 oTo MELARA QUALITY REQUIREMENTS a A Finmeccanica Company August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A The welders must possess basic qualification suitable for the type of material and welding process and be approved by OTO MELARA s personnel who possess the necessary requisites and in compliance with the applicable military standards w 13 6 GENERAL RULES FOR STAINLESS STEEL WELDED JOINTS In addition to the prescriptions related to the definition and qualification of the welding process see also GENERAL REQUIREMENTS FOR WELDED JOINTS AND UNWELDED MECHANICAL ELECTRICAL CONNECTIONS the Supplier shall stick to the following indications The resistance to corrosion of stainless steel is also dependent on condition of the surface which enters in contact with the corrosion environment There are recommended procedure and treatments to polish the stainless steel surfaces either plates that have been laminated hot forged heat treatments or finished items machined or welded etc In both cases it s necessary to polish the surface from slag or dross that prevent it to enter in contact with atmospheric oxygen and then forming the passive layer What above to avoid that once the item is put in the environment localised corrosion events take place The Supplier shall follow the pres
169. the contacts telephone numbers The Supplier or Sub Supplier must provide all the necessary means and assistance to allow OTO MELARA and the Customer to operate at ease and under safe conditions If at the specified date the supply is not available for the envisaged tests and inspection OTO MELARA reserves the right to charge the Supplier all costs incurred for travel and personnel OTO MELARA may also charge the Supplier with personnel costs if tests are repeated in the case of retesting due to repeated non conformities or defects occurring during the preparation and performance of the tests that are attributable to the Supplier such as unsuitable instrumentation or test methods At the end of the tests a report of the test results will be drawn up and countersigned by the Supplier and OTO MELARA s representative and the Customer s representative if envisaged A copy of the test report will physically accompany the product to identify its acceptability status during despatch to OTO MELARA see for example the form in attachment 1 The results of in factory tests contribute to the Vendor Rating The Supplier is required to always ask OTO MELARA Quality for the authorization to send the products even if OTO MELARA Quality does not do the testing at its workshops 7 7 3 Government Surveillance The Supplier undertakes the obligation to admit Government Quality Assurance Representatives for activities envisaged in AQAP AER Q standards that
170. the contents of this document In case the supply is within a program managed by a consortium or a temporary group of firms the applicable quality requirements standards will be treated in dedicated Quality plans agreed between the parties These plans will constitute the main quality reference and will be complemented by this document NOTE This document constitutes a guidance for Company functions to individuate all quality evidences required also for processes carried out in OTO MELARASs facilities apart those aspects intuitively relevant to Suppliers relationship only Y Code 0001 Page 11 of 110 OTO MELARA QUALITY REQUIREMENTS Rev 04 A Finmeccanica Company Date August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A 2 1 CORRELATION TABLE BETWEEN TYPE OF SUPPLY AND REQUIREMENTS CONTAINED IN THIS DOCUMENT commodity class and the applicable sections in this document in order to provide a general picture purely as a reference even if not exhaustive The table allows the Supplier to find the prescriptions related to the intended supply and OTO MELARA to find the control elements to be applied Paragraphs 1 to 9 are generally common to all types of supply paragraph 6 contains the detailed requirements for various coded class of goods divided in criticality classes as per paragraph 5 1 1 In paragraphs 10 717 specific subjects for some kind of supplies are developed For other type of product not m
171. tion can be resumed safely and permanently The Supplier must ensure prompt effective intervention and correct recording thereof in terms of e type of failure malfunction e any replaced parts e the attribution of expenses for RAMS purposes The Supplier must guarantee correct management of spare parts in terms of e compliance with the established stock levels e correct storage In particular the Supplier must guarantee e correct and permanent identification of the spare parts e the correspondence of spare parts to the certifications produced by the OTO MELARA s Supplier and F I F O inventory management where required ambient and physical conditions suitable for the storage of spare parts provision of evidence of the control status the availability of safety data charts where applicable correct storage of technical documents and certifications sent by the OTO MELARA s Supplier and accompanying the spare parts The Supplier must separate the spare parts from non conforming or faulty products to prevent the risk of wrong pick ups from the warehouse or shipping The Supplier must draw up and keep up to date a spare parts list showing the amount of spares in stock for 127 First In First Out RQA0001 103 of 110 7oTO MELARA QUALITY REQUIREMENTS a A Finmeccanica Company August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A each type of product The Supplier is responsible for send reminders to OTO MELARA and its sub
172. tion shall be indicated in technical documents 7 1 2 3 Data retrieval ltem records material processes and controls shall be identified to ease their retrieval 7 1 2 4 Data preservation The recordings must be kept in a safe and accessible place for at least 10 years and 15 years for the documentation of components with critical level 1 RQA0001 y 38 of 110 JOTO MELARA QUALITY REQUIREMENTS 25 August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A 7 1 2 5 Traceability Plan When applicable the Supplier shall prepare a traceability plan listing items and materials requiring serialisation and or lot control explaining methods to assure an effective traceability w 7 2 STORAGE All the necessary precautions must be taken to safeguard integrity of the materials The following rules apply in particular a the stores must be suitable for protecting materials awaiting processing or despatching the materials must be accompanied by the documents tags specified in the internal procedures allowing correct identification and verification of their test status b materials with a limited shelf life must be managed correctly c materials requiring controlled temperature and humidity must be stored in suitable areas d components that are sensitive to electrostatic discharge must be stored in suitable containers in such a way as to safeguard their integrity according to O
173. tivities The Supplier should take great care with stainless steel welds to prevent the risk of contamination in particular the following must be ensured e the stainless steel surfaces must be cleaned thoroughly before welding using special brushes or solvents or pickling agents NJ Code RQA0001 0T0 MELARA QUALITY REQUIREMENTS Page 87 of 110 Rev 04 Finmeccanica Company Date August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A e the electrodes used must be new and used only for this material and constantly controlled for their wear condition e the workplace must be free from contaminating agents The Supplier must e carry out in process controls and record the results on the daily chart at least two specimen at each production start to verify the core diameter request by drawing e check the status of calibration of the test equipment The process used for this type of welding is assessed after executing the various welded specimens for each type of shim coupling All the results obtained will be documented for comparison purposes The reference standards are MIL W 6858 for carbon and stainless steel and AWS C1 1 for aluminium alloys class c non structural UNI EN ISO 15609 5 if not otherwise specified in the order or contract Each test welded specimen shall undergo Inspections and tests including a Visual inspections to check that there is no surface oxidation of the spot molten marks or ma
174. to the OTO MELARA s purchase order and following modifications order issuing date definition of the type of product supplied quantity of products covered by the declaration identification of the manufacturing lot and if applicable the serial number in sequence attributed to individual end products to which the declaration refers assembly drawing and relevant list or parts list with revision index products ID elements required to define the product configuration status compared to the documents approved with an indication of the release of the software installed j reference to the Quality Plan where applicable identified through the code and revision index k reference to the adopted Manufacturing Plan and Control where applicable identified through the code and revision index l non conformities related to the delivered product which agreed solution has been use as is or repair and consequently managed as deviation authorization m references to the list of missing parts if any compared to the end product configuration n reference to FAI Report as far as applicable properly identified by means of identification number and date O certificate issuing date signature of the authorised representative of the company Declaration of Conformity It is hereby certified that the supply complies with the specifications drawings and order to which it refers except for the attached deviations and that it
175. trasporto unitamente agli altri documenti O Collaudo Ricezione competente Gestione Materiali C Acquisti nel caso di collaudo con esito negativo Modulo Cod AQA0019 01 Archivio Identificazione File Rete Aziendale Proc UfE ACOAQOQ019 01 MSW 2003 SP2 N RQA0001 J 105 of 110 OTO MELARA QUALITY REQUIREMENTS 2 A Finmeccanica Company August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A 18 2 ATTACHMENT 2 JOB ORDER DOCUMENTATION MANAGEMENT AND CHANGE INTRODUCTION RECORD example GESTIONE DELLA DOCUMENTAZIONE DI COMMESSA E REGISTRAZIONE DELL INTRODUZIONE MODIFICHE PRODOTTO Nr ORDINE OTO MELARA COMMESSA INTERNA NUMERO TITOLO e o MATRICE DI DISTRIBUZIONE DOCUMENTAZIONE DOCUMENTO ARGOMENTO da OTO Melara Esterna Data Ufficio Contr Produ Acqu Nome Tecnico Qualita zione sti sub SS GESTORE DELLA DOCUMENTAZIONE CONTRATTUALE 2 a gt 2 5 e 2 z RQA0001 106 of 110 oTo MELARA QUALITY REQUIREMENTS A Finmeccanica Company August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A 18 3 ATTACHMENT 3 MANUFACTURING AND CONTROL FORM 18 3 1 Drawing up quidance Reference on Explication 9 Quantity in case of non serialized products or S N in case of serialized products oo 410 J Progressive number of manufacturing and control stage 11 Manufacturing and Control stag
176. ts ii TT Type Tests WPS Welding Procedure Specification ATP Acceptance Test Procedure and relevant Test Report Procedure Qualification Record BT Ballistic Test when required 81 SPC Applied Special Process certificate HTC Heat Treatment Certificate can consist of a certificate relevant to the obtained mechanical characteristics such as hardness resilience tensile strength furnace according to characteristics criticality level STC Surface Treatment Certificate NDT Non Destructive Tests 52 DCC Dimensional Characteristics Certificate T sa QSL Quality System Level Ammunition or its parts produced with OTO MELARA Technical data Package for standard ammunition catalogue see requirements at paragraph 14 2 Complete ammunition QSL AQAP 2110 AQAP 2210 if supply contains parts designed by the Supplier 57 QSL AQAP 2110 AQAP 2210 if supply contains parts designed by the Supplier is When the products are designed by the Supplier and they are not available in a catalogue see also Table 9 85 RQA0001 y QUALITY REQUIREMENTS si of 110 A Finmeccanica Company August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A TABLE 9 INSTRUCTIONS FOR DESIGN SEE PROVISIONS TO ADOPT FOR DEVELOPING THE DESIGN IN COMPLIANCE WITH OTO MELARA REQUIREMENTS MELARA ISO 9001 TSO 9001 TSO 9001 Note 1 These requirements apply to all Commodity Classes when subject of design and developme
177. ts special process specifications Any acceptance procedures issued by the Supplier shall be presented to OTO MELARA for approval Unless specified otherwise on the OTO MELARA s order the records of intermediate and final tests controls shall be filed and kept for at least 10 years from the date of completion of the supply This documentation must allow full data trace ability of the controls carried out as against those carried out by Sub Suppliers up to the final acceptance test 14 1 3 2 Test attendance The Supplier must send to OTO MELARA Quality with a prior notice of at least 10 working days an invitation to attend the test of the object covered by the contract It will be up to OTO MELARA Quality to request during the supply the attendance at any intermediate final tests of the components During these tests OTO MELARA Quality reserves the faculty to choose what components ammunition are to be tested as samples 14 1 3 3 Final tests OTO MELARA Quality must attend the final tests when firing a complete cartridge A conformity audit must also be performed to check compliance with the test requirements specified in the documents supplied by the Supplier and any Sub Suppliers 14 1 3 4 Product identification The products can be identified in compliance with the provisions set out in the technical documentation supplied by OTO MELARA Conformity of identification shall be checked by the Suppliers Quality function that shall re
178. uid lubricants and coolants penetrating liquids fuel oil l products for purification systems acids alkali etc m coolants n fire extinguishing products foam dust etc these charts shall be delivered to OTO MELARA Materials Management together with the first supply Moreover in accordance with the standard EC 1907 2006 the Supplier is required to provide the identification codes for the products materials supplied containing dangerous substances under the standard REACH Registration Evaluation Authorization and Restriction of Chemicals and the related safety data sheets 899 SAFETY DATA CHARTS These charts are used to reduce the risk of on job accidents when handling and servicing materials or products they shall be delivered to OTO MELARA Materials Management together with the first supply They shall contain and comply with applicable law requirement The information recorded on the charts must be entered clearly and concisely for easy consultation Additional information may be required for special compounds whereas for others this information may not be necessary or technically impossible to find in any case this must be justified Any changes made to the safety data chart must be communicated to the recipient of the document The list of materials for which the chart is required must include consumables or maintenance and cleaning products The sequence of the topics to include in the safety data chart is specified b
179. uired to support all the activities envisaged from testing and commissioning of the first sample or prototype made up until achievement of the performance targets including the warranty period for the entire consignment The list of spare parts must be previously agreed with OTO MELARA and drawn up by the Supplier prior to the first consignment The list may be modified to meet the specific requirements of OTO MELARA and its Customer While this is being done the Supplier must provide spare parts through the establishment of appropriate on site stocks which will be managed by OTO MELARA but remain the property of the Supplier These spare parts must be returned to the Supplier on termination of the contract during testing commissioning the warranty period and the performance target verification period In the event of malfunctions defects and or poor quality verified by OTO MELARA and or the Customer OTO MELARA will inform the Supplier when it is necessary to intervene to replace a part If the Supplier is not available to perform the work in the time allowed OTO MELARA will replace and or repair the part itself when possible or have the work done by someone else Intervention by OTO MELARA or any third parties will not affect the Suppliers product warranty i RQA0001 52 of 110 7 MELARA QUALITY REQUIREMENTS August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A T
180. upplier chap 11 provisions to adopt for developing the design chap 12 software chap 01 Edition Introduction of Company new logo no alteration to the content of the QA uly 2006 document QA QA 13 General requirements for welded joints chap 14 ammunition chap 15 manuals chap 16 activities developed by suppliers at OTO MELARA chap 17 activities developed by suppliers at the sites Note The description of the introduced changes is brought in the present page while the signaling of the modified points happens through a segment vertical placed on the edge of the interested page TRACEABILITY DATA QA 039 Company network proc_uff RQA0001 04_E MSW 2010 RQAO0001 a o 4 of 110 ww oto MELARA QUALITY REQUIREMENTS a A Finmeccanica Company August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A CONTENTS 1 DOCUMENT SCOPE AND OTO MELARA PROCUREMENT POLICY 9 1 1 GUIDE TO RQA0001 24 9 2 dec 10 2 1 CORRELATION TABLE BETWEEN TYPE OF SUPPLY AND REQUIREMENTS CONTAINED IN THIS DOCUMENT 2 ao ade 11 3 REFERENCE STANDARDS FOR SUPPLIERS QUALITY MANAGEMENT SOTEM da 12 3 1 SUPPLIERS CLASSIFICATION IN SUPPLIERS LIST 2 2 2 1 13 QOTOMELARA INTERFACES neues 14 4 1 INTERFACE MA
181. urchase of the system e The letter X means to be consigned e fthere are numbers or other words identifying the Work Product or other letters or codes then what has to be consigned is the Work Product applied to the element indicated In the Revision Documentation Stages means System Software Requirements System Software Architecture Test and Validation Procedures Stages means Stages Software Design Code Test and Validation Plans Test and Validation Reports TABLE WORK PRODUCT WP CATEGORIES AND CLASSES identification identification OR ORGANISATION PR PROJECT Criteria Criteria PR 4 Product Design Code Programs data structure PR 5 Material delivered in advance RE DOCUMENTATION Module compiled Minutes of meetings RQA0001 QUALITY REQUIREMENTS d of 110 August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A w O0T0 MELARA A Finmeccanica Company TABLE ll TYPES OF WORK PRODUCT WP The wording Test is to be intended as applicable to SW supply only Approved by OTO MELARA Y Yes or N Not WP Type of Work Description CLASS Product N Description of the System Software development stages their System life cycle software DAD M Project Development Plan Minutes of meeting general Analysis result general Sw safety analysis ES risk management as Quality strategy System and Software Quality Revie
182. ust be delivered to OTO MELARA Quality for verification and approval only prior to arrival of the first lot referring to the same Order and the same job order in the absence of events modifying the application of the documents that documentation must be kept up to date for the entire duration of the supply and thereafter to keep the Supplier List updated The documentation on Non Destructive Tests must be consigned together with the test items When the contents of the typical Manufacturing and Control Plan have been approved by OTO MELARA see typical Manufacturing and Control Plan this document must be used by the Supplier for all deliveries compiled for each manufacturing lot and a copy sent to OTO MELARA together with the envisaged test reports If agreed in advance with the Quality Control of OTO MELARA production site involved the Supplier may following approval of the typical MCP and in partial or total replacement of the personalised MCP present a List of Tests and Inspections RQA0001 54 of 110 oTo MELARA QUALITY REQUIREMENTS a A Finmeccanica Company August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A for each supply as an abstract of the MCP approved and expressed merely as a sequence of the scheduled test and inspection activities w On the Conformity Certificate the Supplier must specify the size of the Manufacturing lot delivered even when it does not cover the entire quantity specified on
183. ust be fully documented The Supplier is also responsible for guaranteeing the logistic and organisational support required for on site maintenance of its software products involving the following types of activity a solving problems b modifying interfaces c expansion of the functions or improving performances These maintenance activities must be recorded in the Configuration Management 12 8 SOFTWARE OWNERSHIP 12 8 1 Software developed by the Supplier The Supplier must ensure that the software supplied is entirely free of copyrights and licences and is provided with the necessary licenses in order to run it without restrictions of any kind The Supplier must provide evidence of the documentation containing the information required for software maintenance and if specifically requested to do so must hand over the source file source code 12 8 2 Commercial Software COTS or Modified COTS The Supplier must ensure that commercial software employed is well established and validated by the market or by the producer and covered by regular user license which allows its transfer to OTO MELARA and end users with no additional charges for OTO MELARA and its customers and without incurring to any violation of applicable laws RQA0001 75 of 110 MELARA QUALITY REQUIREMENTS a A Finmeccanica Company August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A 12 9 APPLICABLE REQUIREMENTS The section defines the act
184. volved 8 STQ Technical Services of Quality only at La Spezia plant QPM Quality Program Manager RQA0001 19 of 110 oTo MELARA QUALITY REQUIREMENTS a A Finmeccanica Company August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A 5 MELARA REQUIREMENTS IDENTIFICATION AND CORRELATION WITH SUPPLIER S QUALITY MANAGEMENT SYSTEM w 5 1 CLASSIFICATION In the technical data package issued by OTO MELARA each item unit assembly etc reports an indication constituted by a a numeric code identifying the criticality class in terms of safety shown in the title block of the drawing and or in the parts list b aletter identifying the class of goods in terms of quality requirements shown on a dedicated drawing legend and or parts list For example A1 means material critical for the safety number 1 of Non metallic indefinite material letter A 5 1 1 Criticality Level The criticality level which is shown on the drawings additional legend and or the parts list or on an associated list is a classification attributed to the item unit or assembly according to the impact on mission safety or operations in case of failed or wrong operation malfunction or yield The attribution takes the following into account a Results of safety analysis conducted according to methods described in international standards and appearing on filed documents b degree of mechanical stress or electric
185. w of documents general Strategy Re utilization requirements Re utilization plan System requirement specification Software requirement specification PR 2 Software design specification inputs outputs and the correlation between stages Rules applied for writing the software s source code style restrictions use of notes Description of the aims activities dependences resources times responsibilities system software development and production inputs and outputs Interventions and important decisions passed at the meeting General this applies to each subject referring to a project Results from the analysis of a work product according to defined criteria General this applies to each WP Y Depending on the WP Y N Sw safety analysis of the whole product Organisational rules identify analyse manage any project risks This defines the quality objectives and the means and resources to control and facilitate their achievement Report on the review of the results of The approval each project stage or activity depends on the General this applies to each stage or stage with reference activity o what established in the Quality Plan This sets out the rules requirements and limitations for the reuse of a system software This defines the re utilisation objectives and actions resources in order to achieve the set objectives interventions for acquiring system sub
186. w verification of the geometrical mechanical and electrical features They may be comprised of parts subjected to internal pressure They allow the performance of a functional test with the relevant measurements if required 5 4 22 3 Lifting equipment YS These are devices used to lift the product in its final configuration or any parts thereof i RQA0001 28 of 110 MELARA QUALITY REQUIREMENTS d A Finmeccanica Company August 2012 0 4 22 4 Logistic equipment YM These are devices that allow the execution of maintenance tasks described in the maintenance plan developed for the product and or troubleshooting of the equipment that makes up the system w 6 SYNOPTIC TABLES FOR COMMODITY CLASSES WITH RELEVANT REQUIREMENTS FOR ACTIVITIES AND DOCUMENATION REQUESTED WITH THE SUPPLY AND RELATED TO THEIR CRITICALITY LEVEL Requirements related to activities and documentation certification to be supplied to OTO MELARA are defined according to commodity and criticality classes paragraphs 5 4 and 5 1 1 Requirements reported in the following synoptic tables are to be considered as the minimum required to the Supplier in the absence of more precise indications or needs expressed by the right Company function Requirements refer to different times phases a Before starting production in the act of accepting the order with the aim to take a view and control of the manufacturing process to introduce possible corrections
187. ware CAD CAE and CAM interface problems arising out of the development of the design and requiring OTO MELARA s specific authorisation before starting any related activity p provide OTO MELARA with the elements and data that allow an evaluation of the consequences following authorisation to design changes involving the Supplier at any title approval by OTO MELARA of major changes with an impact on interchange ability Form Fit and Function information and possible reclassification of minor changes w It is forbidden to the Supplier the outsourcing of activities provided by the Order unless previously authorized by OTO MELARA 11 2 INSTRUMENTS USED BY OTO MELARA FOR COORDINATION AND SUPERVISION OTO MELARA intends to coordinate and supervise the design activity through technical meetings approval of the Project Development Plan participation to the Design Review design expediting meetings and verifications acquisition of design documents acquisition of document lists defining the configuration baseline RQAO0001 71 of 110 Finmeccanica Company August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A approval of the verification and validation plan approval of calculation and sizing analyses and reports attendance at type tests system and process audit w MELARA reserves the right to apply penalties for any delays on the development sch
188. ween two holes a profile etc it is acceptable that the dimensions is verified on the first part machined as validation of NC part program Operator responsibility dimension dimension obtained through the skill of the operator operator responsibility dimension i e diameter of a tolerate hole which depends on tool setting or sharpening shall be checked for each part machined 124 i RQA0001 58 of 110 7 oto MELARA QUALITY REQUIREMENTS 2 A Finmeccanica Company August 2012 QUALITY REQUIREMENTS FOR SUPPLIES TO OTO MELARA S p A 8 6 2 Typical Manufacturing and Control Plan See also MANAGEMENT OF CONTRACT DOCUMENTATION AND DOCUMENTATION REQUIRED BY OTO MELARA Typical MCP means a plan with characteristics under subsection see MANUFACTURING AND CONTROL PLAN MCP That is typical for a certain supply or recurrent in several lots of supply this document can be used following an agreement with OTO MELARA Quality at the preliminary supply definition stage in replacement of the personalised MCP called in short as MCP for the specific supply after its complete definition w 8 6 3 Check stamps The Inspection and Production Stamps issued to authorized holders must be recorded with the sample signature of the holder and with the definition of the approval purpose for which the stamp must be used If the stamp is withheld for any reason it must not be released again for at least six months and the reason of the withhold
189. worked repaired and comply with the specifications the drawings and the order to which they refer with the exception of the attached deviations and they have been inspected and tested according to the terms and conditions and requirements stated in the initial order no or the specific order no 7 11 6 Notification of non compliance related to products delivered Quality Alert The Supplier must send a statement of Quality Alert written on its headed paper to notify OTO MELARA about any circumstances that may affect the integrity of the product previously delivered or any errors or lack of Use and Maintenance Manuals that may affect the use and or maintenance of the product The information must be sent to OTO MELARA more specifically to Head of Design Head of Customer Logistics Quality Manager 7 12 LIABILITY FOR SUB SUPPLIERS MANAGEMENT If the Supplier delegates certain activities to Sub Suppliers it must guarantee a the Sub Supplier s skill and capability to develop the assigned part of the contract b the correct and complete transfer of all OTO MELARA s specifications applicable to the Sub Supplier by means of this document OTO MELARA will in all cases consider the Supplier responsible for poor quality or any delays in the supply including the documentation and reserves the right to apply to the Supplier the penalties established in the Contract or Purchase Order The Sub Suppliers must also guarantee c

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