quality control

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MISSION STATEMENT

It is our mission at Brooks Machine Products Ltd. to provide our customers and ourselves the best machined product available at a reasonable price and deliver that part on time. We will strive to please our customer's requests for quality and timeliness while maintaining the integrity of all parties concerned. Designs and procedures will be continually scrutinized for engineering improvements and safety.

We pride ourselves in our ability to manufacture in an organized layout with well-maintained equipment and the best safety and cleanliness we feel that is important for efficiency. We welcome our customers to visit our facility any time.

 

QUALITY STATEMENT

This Quality Manual is designed as a guide in maintaining proper manufacturing and inspection control at a high standard of quality on items manufactured at Brooks Machine Products Ltd. It will also provide assurance to its customers that through this control their requirements will be satisfied.

The following documents are our written procedures to insure control of sub-contractor manufacturing in accordance with military specifications, where applicable, and within our control.We certify that we manufacture in compliance with the following quality standards:

  • FAR 21
  • MIL-STD-105
  • MIL-I-45208
  • MIL-C-45662A
  • MIL-Q-9858

 

ORDER OF PRIORITY

The customer's purchase order, supplied prints, requested standards, and special requirements shall take precedence in the fabrication and processing of material covered by the subject order.

In the event that no special specification or requirements are requested in the manufacturing process, it will be the responsibility of the contracted suppliers to conform to industrial standards of quality. (For example, heat treat and plating requirements.)

 

CONTROL OF DRAWINGS AND SPECIFICATIONS

Upon receipt of a customer purchase order, this order shall be received by the production manager and examined for conformity to the latest engineering change, revision, and current specifications.

At this time all process sheets, blueprints, special tools and process requirements shall be issued to manufacturing. Inspection procedures, requirements and forms will also be issued to manufacturing to insure conformity to blueprints and process specifications.

In the event of an engineering change, the production manager shall immediately notify engineering, production and quality control of such changes and shall recall all of the obsolete prints and specifications for replacement.

The obsolete materials shall then be destroyed.

RECEIVING INSPECTION

It shall be receiving's function to inspect all material entering the plant for conformity to specification, size, quality, etc.

This material may not leave the receiving area untill proper inspection is made and the material is properly identified and tagged, marked, etc. as established procedure.

Defective material shall be identified as such and be held separate for dispostion. Receiving inspection shall maintain adequate records for positive identity and control of all incoming material.

After acceptance of parts or material, these records will be transferred to the permanent files of the shop general manager.

Control of parts is carried out normally with the use of.color coded instruction tags; red being scrap, green is OK for stock, and yellow for rework or special instructions or information.

 

CONTROL OF RAW MATERIAL

As was discussed under the heading of Receiving Inspection, no raw material shall reach inventory without proper inspection and identification.

This identification includes part number, type, and specification. Issuance of raw material can be made only through production control.

The production routing, blueprint and other instructions accompany raw material to the initial stage for processing.

This information remains with the material throughout the entire processing cycle, with the exception of outside services, during which time this information is held in the part number folder until material is returned.

 

CUSTOMER PROPERTY

All government or other manufacturing companies that furnish or own tooling and/or gaging equipment must be properly identified immediately.

It must then be stored in the designated area for such property and be properly preserved when not in use.

This equipment shall be inspected prior to usage or at such time as the customer requires periodic inspection.

 

DISCREPANT MATERIAL

Any parts or materials found to be discrepant during any state of manufacture or at final inspection shall be identified immediately and moved to a holding area until disposition is made.

The procedure for disposition is as follows:

  • A material review action request or case record is made with the following information supplied:
  • Specifications, discrepancy, number of parts involved, case, and corrective action.
  • This information is then submitted to the customer for disposition, such as: use as is, rework or scrap. After these instructions are carried out, the parts are reidentified, and the normal processing continued, but seperately from other non-discrepant parts of materials.
  • Control of parts is carried out with the use of color coded instruction tags, red being scrap, green is OK for stock, and yellow for rework, special instructions or information.

PURCHASE ORDER FILE

Complete records are maintained for each job manufactured in the sales office part files.

These files are set up with receipt of the purchase order, and as the job is completed, the pertinent paper work is filed in the part file to which it applies.

The following information is included in each part file as required:

  • Copy of customer's purchase order and all ensuring amendments.
  • Copy of customer's print.
  • Original Operation Sheet.
  • Manufacturing Layout.
  • Copy of certifications when required, covering material and/or processing.
  • Inspection reports, including First Article Inspection.
  • Original and subsequent quotations.
  • Records will be retained for a minimum of 7 years or longer if required by customer.

PURCHASING CONTROL SECTION

It is the responsibility of the purchasing department to order raw material and special processes, such as heat treat, plating and non-destructive testing, and to require vendors to furnish proper certifications of compliance with applicable specifications.

Request for certification of material will be included in purchase orders as required.

Acceptable methods of certification are as follows:

  • For raw material - actual test reports showing the chemical and physical characteristics of the material.
  • For processes - a statement by the supplier that sample tests have been conducted in accordance with applicable customer and/or military specifications, and that such tests are on file and available for inspection, and that compliance with the required specifications has been achieved.
  • Independent laboratory analysis of materials upon request conducted in accordance with customer specifications.
  • All material orders are placed by purchase order.
  • The original material certifications are placed in the sales office master job folder
  • Only customer-approved subcontractors shall be used when specified by purchase order of specification, for any process not completed in our facilities. All customer specifications shall be forwarded to the subcontractor for each item he is to process.

Sampling plan used by final inspection areas based on MIL Spec 105 D Adjusted AQL 1.0 Level ll LOT SIZE SAMPLE SIZE ACCEPTED REJECTED 1 - 8 100% 0 1 9 -15 8 pcs. 0 1 16 - 25 8 pcs. 0 1 26 - 50 8 pcs. 0 1 51 - 90 13 pcs. 0 1 91 - 150 20 pcs. 0 1 151 - 280 32 pcs. 1 2 281 - 500 50 pcs. 1 2 510 - 1200 80 pcs. 2 3 1201 & over 125 pcs. 3 4

IN PROCESS INSPECTION

The quality department shall provide inspection at various stages of manufacturing to insure proper quality standards.

Such inspection shall consist of through analysis of set ups and regular spot checks throughout the cycle.

At no time shall an inspector accept an operator's computed processing dimension or any other deviation from the blueprint of process route sheets.

All inspectors are to identify all parts inspected with an initial stamp provided for this purpose as required.

 

PROCESS CONTROL

We provide contract services to an extensive and varied customer base.

Due to this, we have a few customers whose products do not require documented process control. Of those customers who do require document process control, unique lot numbers will be assigned to each production run of parts ordered.

Furthermore, all paperwork i.e. time cards, process sheets, material certifications, inspection reports, heat treat certifications and finishing certifications will show this unique lot number.

Specific process sheets may be supplied to the customer.

If process sheets are not provided, but required, Brooks Machine Products will develop a process for manufacturing and produce the required process documention.

MANUFACTURING LOT NUMBERS

When each new purchase order is entered into our system, a Manufacturing Lot Number is assigned to the part.

That lot number follows the entire paperwork trail including outgoing paperwork.

If there is a change in any material lot number during the production run, a new separate lot number is assigned to clarify the new material manufacturing lot number.

This allows for complete traceability of every single part and each lot number to the material mill source.

 

FINAL INSPECTION

The quality department shall cause all items under contract to be subject to final inpsection.

This inspection is to be performed in the established inspection area and to be conducted by qualified personnel. Unless otherwise specified by contract, specification or other practical reasons, this operation shall be performed in accordance with MIL-STD-105 of other approved or acceptable sampling plan.

See inspection sample schedule. The first article of the lot shall be 100% inspected and the exact findings shall be recorded prior to lot sampling.

Sample plan results shall be recorded on forms provided for this purpose and shall be filed in the inspection job folder with other pertinent data for future reference.

The inspection department shall provide 100% visual inspection of all parts and material immediately prior to packaging to preclude the possiblility of shipping parts damaged by handling.

Also, they shall review and present for packaging all necessary completed forms and certifications, as required by the customer, unless otherwise specified.
    •    First Article Inspection
    •    Inspection Report

INSPECTION DEPARTMENT

Our facilities consist of the following:
    •    14" Floor model MicroVue Projector Comparitor w/ DRO
    •    Granite inspection grade surface plate
    •    Trimos 18" digital height gage
    •    Gage pin sets
    •    Gage block sets & master blocks
    •    Browne & Sharp Super Micrometer 12"
    •    Sheffield Electronic Comparitor
    •    Small dial indicators
    •    Dial bore gages

 

GAGE INSPECTION FREQUENCY

ANNUAL CERTIFICATION      3 MONTH INSPECTION
Surface plate,granite            Micrometers
Height gage,digital               Verniers
Super Micrometer                Dial Indicators
Gage block sets
Gage pin sets
Sheffield comparator
MicroVue projector
Thread gages

Special gages such as snap gages, squareness gage, profile gages, etc. are checked before each use with masters supplied with gages or to print requirements as applicable.

GAGE CONTROL SECTION

1. Standards for calibration measuring and testing equipment used in controlling product quality shall have the capabilities for accuracy, stability, and range required for the intended use. All calibration performed will be traceable to the National Bureau of Standards.

2. Calibration of gages and test equipment at this facility will be accomplished under ambient condition giving due consideration to temperature and cleanliness and other factors affecting precision measurements.

3. Gages and testing equipment calibrated by an outside source are calibrated under controlled temperature, certified, and traceable to the National Bureau of Standards.

4. Records and/or certifications are available for inspection. Calibration intervals for measuring and testing equipment and meassurement standard have been established on stability, purpose, and degree of usage.

5. Calibration methods are performed in accordance with manufacturer's written instruction, MIL-STD120, and by comparison with higher level standards.

6. Obsolete equipment is withdrawn from service, identified and the gage control card recorded as inactive. Damaged and/or inaccurate equipment is withdrawwn from service, identified, repaired or scrapped, and the gage control card is recorded as to disposition.

7. Records are maintained on all calibrations by the use of gage control cards. As a minimum, the gage control card will contain the following information: Identification of the item, calibration interval, Date of last calibration, Date of next calibration, Results of calibration and calibration report of certificate number of those items calibrated by an outside source. These records are maintained in the inspection department and are availible for all authorized representatives.

 

 

 8. All gages and test equipment used for inspection acceptance are labeled with a calibration sticker, showing the date of last calibration, by whom it was calibrated and the due date of next calibration.

9. When size or functional characteristics limit the application of labels, the code number label on the gage shall be used to reference back to the respective gage control card.

10. All personal measurement equipment such as verniers, micrometers, etc. used by employees are to be inspected by an authorized inspector using traceable master blocks. Results recorded on gage control cards.

11. Notification of out of tolerance conditions: When measuring or test equipment is found to be out of tolerance, the quality control manager determines if the degree of out of tolerance condition could affect quality of product produced using said equipment. It is the quality control manager's responsibility to take appropriate actions.

12. Tool inspection: Tooling if required, l is inspected prior to use. Fixtures, on request are inspected prior to use.

13. When and if a fixture or jig is used as a media of inspection acceptance, calibration will be followed as if it were an inspection gage.

INSPECTION EQUIPMENT PROGRAM

We annually have Thomas Cirmo of TAC Calibration Services of Binghamton, NY, inspect the following equipment at our facility:

MicroVue 14" Optical Comparitor with DRO & edgefinder
Fowler Trimos 10" Digital Height Gage model TVM300
Tru-Stone 2'x3' Grantie Surface Plate
Shefield Height Comparitor model 1000
Pratt & Whittney Supermicrometer model M1471
All traceable to NIST with appropriate control numbers
We also annually inspect the following gage pins and blocks using the supermicrometer:
Meyer Gage Pins model M-0 Plus    .011-.060
Vermont Gage Pins model B Plus    .061-.250
Vermont Gage Pins model C plus    .251-.500
Meyer Gage Pins model M-2 Minus   .251-.500
Fonda Gage Blocks model 37S       .1000-4.0000
HDT Gage Blocks model 81234       .050-4.0000

Gage pins are inspected for size, taper, hourglass, and burrs. If it fails any of the above conditions more than .0002", the gage is replaced. A complete documentation is on record and available in our office.

All other gaging equipment is checked every 90 days and documented on index cards. These include all of ours as well as the employees personal:

Digital and Dial Verniers (6"-12")
Digital and Vernier Micrometers (0"-6")
Dial Indicators (.0001"-.001")
Depth Micrometers (0-6")
Depth Micrometers (0-6")
Bore Gages (1"-6")
Drop Indicators (0-2")

EQUIPMENT LIST

CANON NP1020 Copy Machine
PANASONIC UF150 Phone/Fax Machine
BROTHER EXECUTRON 68 Typewriter
BROTHER GX 9000 Typewriter
Computer Stations (3 IBM Compatible)

MITSUBISHI RA 90   4 AXIS CNC Wire Cut EDM 2002
BRIDGEPORT VERTICAL MILL With "J" Head & MITUTOYO DRO
BROWN & SHARP NO. 2 Horizontal Milling Machine
MHP CNC Vertical Machining Center W/24 Station Tool Changer
    & Accessories  1986
SUNNEN MBB 290D Hone With Accessories  
CINCINNATI NO. 2 Tool & Cutter Grinder
ELGIN ALPA RT 450 Hydraulic Surface Grinder
CLAUSING 4020 Hydraulic Surface Grinder  
Pedestal Carbide Grinders  (3)
MHP TURNEX 2 CNC High Precision Turning Center with Chucker
     and Bar Feed  1988
REPUBLIC LAGUN 14" Gap Bed Engine Lathe with most Attachments
    including HOLDRIDGE RADII-CUTTER
SHELDON 14" X 30" Tool Room Engine Lathe  
SCHAUER Speed Lathe for Polishing
CLAUSING 20" Floor Model with Variable Speed, Power Down
    Feed, and QUADRILL & QUINDRILL Attachments  
DELTA Floor Model Drill Presses (5)  
DELTA Bench Model Drill Press  
DUMORE AUTO Drilling and Tapping Machine

 

V & O 35 Ton Punch Press   Continuous Feed or Single Stroke  
NIAGARA A3 1/2 50 Ton Punch Press  (2)         Cont. or Single
NIAGARA A3 32 Ton Punch Press               Cont. or Single  
NIAGARA A2 1/2 22 Ton Punch Press   (2)     Cont. or Single
NIAGARA H2 1/2 22 Ton Horning Punch Press            Single
NIAGARA H2 14 Ton Horning Punch Press                Single
HANNIFIN L-2090 15 Ton Hydraulic Riveting Press  
NUGIER 30 TON H-Frame Hydraulic Press
NIAGARA 6' Power Shear
CHICAGO 4' Box and Pan Brake
DI-ACRO 12" Precision Shear
DI-ACRO 18" Precision Box and Pan Brake
DI-ACRO 6" 90 Degree Notcher
Assortment of Coil Feeds, Stock Feeds, and Scrap Reelers for
automatic production punch press jobs
VICTOR Horizontal Cut-Off Saw  1989  
LINCOLN IDEALARC TIG 300A Heliarc and Stick Welder
REEVES/CROWN Wet Tumblers  (2)
SWECO 2 Cubic Foot Vibratory Tumbler  
Dry Tumblers   (2)
ROCKWELL/DELTA 20" Bandsaw
BUTTERFLY Filing Machine
ROCKWELL/DELTA Belt Sander   (2)