UNCONTROLLED DOCUMENT - Amazon S3 · 108 Production Part Approval Process (PPAP) ... UNCONTROLLED DOCUMENT. ... 602 Engineering Change Notice Procedures 0

Rheem Manufacturing Company

Fort Smith, Arkansas

Original Release: 4/06/09

Revision Date: 9/30/16

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Quality Management System Procedures Title: Reviewed by: Revision No.: Page:

Quality Management System Procedure

Contents

D. Presley 28 1 of 2

Approved by: Effective date: Document Number:

A. Johnson 9/30/16 0

Applicability:

Rheem Air Conditioning Division

Document

Number Title Revision

0 Quality Management System Procedure Contents 28

100 Preparation, Release, and Control of Quality Management System Procedures 1

101 In Process Inspection 0

102 Corrective and Preventive Action Report 2

104 Nonconforming Material - Components 3

105 Calibration and Control of Inspection, Measuring, and Test Equipment 1

106 Quality Management System Audit 1

107 Internal PPAP (Production Part Approval Process) 1

108 Production Part Approval Process (PPAP) 5

109 Scrap Procedure 4

110 Data Acquisition Network 2

111 Supplier Assessment 3

112 Non-Conforming Materials - Finished Goods 2

113 Document Control 2

114 Quality Records 1

115 Final Inspection and Testing 0

116 Receiving Inspection 2

117 Quality Assurance Process Audits 1

118 Statistical Techniques 0

202 Rheem Fort Smith Total Productive Manufacturing 1

203 Routing and Order For Press Parts 1

204 Process Control 1

300 Human Resources 2

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Quality Management System Procedure

Contents

D. Presley 28 2 of 2


A. Johnson 9/30/16 0

Applicability:


301 Human Resources Record Keeping Procedure 1

302 Human Resources Staffing Procedure 1

400 Handling, Storage, Packaging, Preservation, and Delivery 1

401 Product Identification and Traceability 1

500 Purchasing Supplier Control 1

501 Purchasing – Buying Plan Change Request 0

600 Product Audit Procedures 2

601 Deviation Request Procedures 2

602 Engineering Change Notice Procedures 0

603 In-Process and Final Test Procedure 0

604 Design Development, Product Maintenance, and Product Development 0

700 Contract Review 2

701 Customer Reporting Systems 0

1000 Glossary 1

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Quality Management System Procedures Title: Review by: Revision No.: Page:

Preparation, Release, and Control of

Quality Management System Procedures D. Presley 01 1 of 2

Approved by: Effective date: Document No.:

B. Gahr 7/22/14 QMSP 100

Applicable to:

Rheem Air Conditioning Division – Ft. Smith

1.0 Purpose

1.1 The purpose of this procedure is to define the format, content, and numbering system used to generate and control all

Quality Management System Procedures.

1.2 This procedure applies to all system procedures that become a part of this Quality Management System Procedure

Manual.

2.0 References:

2.1 None

3.0 Definitions:

3.1 See Section 1000, Glossary, for definitions.

4.0 QMSP Requirements:

4.1 Quality Assurance will control and issue all procedure numbers.

4.2 Any individual or department can initiate a System Procedure.

4.3 Quality Assurance will maintain a log of procedure numbers and titles. The following number system will be used:

(QMSP) Procedure Numbers Responsible Area

100 Manufacturing Plants

200 Manufacturing Engineering

300 Human Resources

400 Traffic/Shipping

500 Purchasing/Materials

600 Research & Development

700 Sales/Marketing/National Service

800

900

1000 Glossary

4.4 When a procedure affects another department or facility, it must be reviewed in draft form by that department or

facility prior to final release.

4.5 Approval of procedures must have the signature of the Department Manager or his appointed representative. The

Quality Management System Manual and Quality Management System Procedures will be distributed electronically

through the use of MyRheem.Com. A master copy will be maintained by the Quality Assurance Manager.

4.6 The procedure writer will enter N/A under any section that does not apply.

4.7 Any procedure relative to the Quality Assurance System will have to be reviewed by the Quality Assurance Manager

to ensure ISO 9001:2008 compliance.

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Preparation, Release, and Control of

Quality Management System Procedures D. Presley 01 2 of 2


B. Gahr 7/22/14 QMSP 100

Applicable to:


5.0 Responsibilities:

5.1 It is the responsibility of the Quality Assurance Department to ensure compliance to this procedure.

6.0 Quality Records:

6.1 Quality Management System Procedures

7.0 Revision History:

Revision Description Effective Date 00 Initial issue of ISO 9001:2008 4/06/09

01 4.5: Replaced “the local Rheemote.Net” with “MyRheem.Com”

4.6: Removed 4.6 from the procedure

7/22/14

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In Process Inspection R. Werschky 0 1 of 2 Approved by: Effective date: Document No.:

D. Thresher 4/06/09 QMSP 101 Applicable to:


1.0 Purpose:

1.1 The purpose of this procedure is to establish the control and acceptance for work in progress. 1.2 This procedure applies to all products produced for use in end item that will be shipped to a customer.

2.0 References:

2.1 Quality Management System Procedure 102, Corrective and Preventive Action Report 2.2 Quality Management System Procedure 104, Material Review Process Board

3.0 Definitions:

See Section 1000, Glossary, for definitions.


4.1 The inspector will select a random sample from the production lot and perform a visual and functional inspection. 4.2 The inspector will use the guidelines of the Control Plan and Inspection Work Instruction to insure conformance to

the requirements. 4.2.1 Production will follow the guidelines of the Control Plan and Work Instructions when applied to their area. 4.2.2 In-process functional tests are uniquely identified by the individual performing the tests. Test results are

documented in accordance with control plans. 4.3 The Production Foreman will insure that all employees responsible to him/her are made aware of the importance of

using proper methods, tools, materials, processes, and good workmanship in the fabrication of all parts, sub-assemblies, and final assemblies.

4.4 Production will insure that the first piece has been accepted per Control Plan and/or Inspection Work Instruction prior to any production run. In the event of trial production for Field Testing, product will be held for R&D review and release. 4.4.1 Production shall insure operators perform inspection of the product at the appropriate stations.

Nonconforming product will be held and reviewed per QMSP 104. 4.5 Should a selected sample be defective, Production Supervision will be notified.

4.5.1 Production Supervision will stop the machine operation, if necessary. 4.5.2 Corrective action will be issued according to QMSP 102, if necessary 4.5.3 Production will respond to the corrective action as required and correct the discrepant condition. 4.5.4 After disposition of corrective action and the discrepant condition is corrected; Supervision will have the

machine operator to run a new sample of parts and prior to resuming production insure part conforms to specification.

4.6 Defective production will be documented.

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In Process Inspection R. Werschky 0 2 of 2 Approved by: Effective date: Document No.:



4.7 All non-conforming product, unless reworkable, will be identified and segregated until disposition is granted by Production or the MRB in accordance with QMSP 104.

4.8 Reworkable production will be designated by tag QA-004 and shall meet Engineering Specifications upon rework.


5.1 It is the responsibility of the Quality Assurance Department to insure compliance to this procedure. 5.2 It is the responsibility of the Production Department to insure that each process, sub-assembly, and fabricated parts

meets all of the customer, Engineering, and Quality requirements.


6.1 Material Review Database 6.2 Inspection Log 6.3 Corrective and Preventive Action Report (CAR-001) 6.4 Data Acquisition 6.5 Repairable Material Tag (QA-004)



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Corrective and Preventive Action Report D. Presley 02 Page 1 of 2


B. Gahr 8/29/14 QMSP 102

Applicable to:


1.0 Purpose:

1.1 The purpose of this procedure is to specify a system for informing appropriate personnel of instances of

nonconformance or potential nonconformance to quality requirements and to initiate corrective or preventive action.

1.2 This procedure is applicable for formal reporting of corrective and preventive actions regarding: external customers,

internal customers, internal quality systems, and suppliers.

1.2.1 A means to initiate investigation as to root cause of nonconformities relating to products, components,

processes, and the quality system.

1.2.2 Determination of the corrective action needed to eliminate the causes of nonconformities.

1.2.3 Determination of the preventive action needed to prevent possible nonconformities.

1.2.4 Application of controls to ensure corrective or preventive action is taken and is effective.

2.0 References:

2.1 CRIS: Customer Record Information System

2.2 ECN: Engineering Change Notice

2.3 Quality Management System Procedure 701, Customer Reporting Systems

3.0 Definitions:



4.1 A Corrective Action Report (CAR) can be initiated to investigate the cause of a material, product or software

discrepancy, customer complaint, or supplier quality issue resulting in the recommendation of corrective action so as

to avoid the recurrence of the discrepancy.

4.1.1 A CAR may be issued to address a potential discrepancy prior to occurrence. Preventive action is

addressed through the review of Capability Studies, Last Part Inspections, Maintenance Records,

Audits, Customer Complaints, etc. to analyze and eliminate potential causes of nonconformities.

4.2 Any department or individual may request corrective or preventive action. An optional CAR worksheet is available

that can be used by the department or individual requesting the corrective or preventive action.

4.2.1 The Quality Assurance contact will decide if a CAR is needed or if the problem can be resolved

otherwise.

4.3 When the (CAR) is initiated, the Quality Assurance Department initiate in the Reliance system will log it in the

Corrective Action Database.

4.3.1 The (CAR) may be categorized as customer, internal, DTR, or supplier related. There can be a

corrective or preventive type.

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Corrective and Preventive Action Report D. Presley 02 Page 2 of 2


B. Gahr 8/29/14 QMSP 102

Applicable to:


4.4 (CAR) is forwarded to the assigned organization where an investigation is done to detect and document the root

cause of the discrepancy, and the action taken to prevent recurrence. The implementation date will be set by the

organization responsible for the corrective action. In both cases the reply will be in an electronic format.

4.5 The internal, DTR, or customer Corrective Action Report will be returned within seven (7) days from the date

of issue to the Quality Assurance Department. The Supplier Corrective Action will be returned within fourteen

(14) days from date of issue.

4.6 Quality Assurance will perform a follow-up Audit after the date of implementation to ensure Corrective Action

has been completed and effective for internal and customer Corrective Actions.

4.7 If the internal, DTR, or customer Corrective Action Report is not returned to Quality Assurance within seven

(7) days a reminder will be sent to the CAR assignee and copied to the next higher level of responsibility. If the

Supplier Corrective Action is not been returned after fourteen (14) days, Quality Assurance is to send a

reminder to the Supplier. If the form has not been received after thirty (30) days, Purchasing will send an

additional reminder and may choose to withhold future acceptance of shipments until the reporting requirement

is complied with.


5.1 The tracking of this procedure is the responsibility of the Quality Assurance Department.


6.1 Corrective and Preventive Action Report (CAR-001)

6.2 Corrective Action Database


Revision Description Effective Date

0 Initial issue of ISO 9001:2008 4/06/09

01

4.3.1 Inserted: DTR, 11/10/10

4.3.2 Inserted: DTR, in Category:

Inserted: PSS Contact: Enter name of Product Support Contact.

4.5 Inserted: ,DTR,

4.7 Inserted: ,DTR,

02 4.3 Inserted: initiate in the Reliance system 8/29/14

Removed 4.4

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Corrective and Preventive Action Report R. Werschky 01 Page 3 of 4 Approved by: Effective date: Document No.:

R. Turner 11/10/10 QMSP 102 Applicable to:


Immediate Action: Enter a brief description of actions taken to contain the problem (memo field). This can be described as the efforts necessary to prevent the problem from being part of the next shipment such as an extra inspection or test or rework. C/A Assignee: Enter the name of the person responsible for implementing the corrective action. (mandatory)

C/A Department: Enter the department of the corrective action assignee from the list. (mandatory) Root Causes: Enter the results of the root causes analysis (memo field). Corrective Action: Enter a brief description of actions taken to reduce the probability of the problem from reoccurring (memo field). This action should eliminate the need for the immediate solution continuing. The goal is to ensure this problem will not have to be addressed again. Follow-Up: Enter the action taken to assess how effective the corrective or preventive action was in solving the problem. Response Due Date: Enter the date the initiator requests to have a corrective action plan to be submitted (default is 7 days after Date In and can be changed). (mandatory) CAR Submit Date: Enter the date by which the CAR plan was actually submitted. CAR Approval Date: For Internal and Supplier CAR, enter the date by which corrective action plan is approved. The Quality Assurance contact can choose to get approval consensus with the CAR initiator. Implement CAR Plan Date: Enter the date by which the corrective action is to be implemented. Follow-Up Plan Date: Enter the date by which the follow-up investigation is to be completed. Closure Date: Enter the date on which the follow-up action was completed. A date in this field closes the CAR. If the Quality Assurance representative performing the follow-up finds the Corrective Action has not been effective, the CAR will not be closed. Comments: Enter general comments such as status conditions.

4.4 (CAR) is forwarded to the assigned organization where an investigation is done to detect and document the root cause of the discrepancy, and the action taken to prevent recurrence. The implementation date will be set by the organization responsible for the corrective action. In both cases the reply will be in an electronic format.

4.5 The internal, DTR, or customer Corrective Action Report will be returned within seven (7) days from the date of issue to the Quality Assurance Department. The Supplier Corrective Action will be returned within fourteen (14) days from date of issue.

4.6 Quality Assurance will perform a follow-up Audit after the date of implementation to ensure Corrective Action has been completed and effective for internal and customer Corrective Actions.

4.7 If the internal, DTR, or customer Corrective Action Report is not returned to Quality Assurance within seven (7) days a reminder will be sent to the CAR assignee and copied to the next higher level of responsibility. If the Supplier Corrective Action is not been returned after fourteen (14) days, Quality Assurance is to send a

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Corrective and Preventive Action Report R. Werschky 01 Page 4 of 4 Approved by: Effective date: Document No.:

R. Turner 11/10/10 QMSP 102 Applicable to:


reminder to the Supplier. If the form has not been received after thirty (30) days, Purchasing will send an additional reminder and may choose to withhold future acceptance of shipments until the reporting requirement is complied with.


5.1 The tracking of this procedure is the responsibility of the Quality Assurance Department.


6.1 Corrective and Preventive Action Report (CAR-001) 6.2 Corrective Action Database



0 Initial issue of ISO 9001:2008 4/06/09 01 4.3.1 Inserted: DTR, 11/10/10 01 4.3.2 Inserted: DTR, in Category: Inserted: PSS Contact: Enter name of Product

Support Contact. 11/10/10

01 4.5 Inserted: ,DTR, 11/10/10 01 4.7 Inserted: ,DTR, 11/10/10

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Nonconforming Material -- Components D. Presley 03 1 of 3


A. Johnson 9/30/15 QMSP 104

Applicable to:


1.0 Purpose:

1.1 This procedure describes the systems for identifying and segregating purchased, fabricated or assembled components

(in-process and completed) that have been found to be nonconforming and questionable as to fit for use.

2.0 References:

2.1 QMSP 102, Corrective and Preventive Action Report

2.2 QMSP 109, Scrap Procedure

2.3 QMSP 112, Finished Goods Reinspection

2.4 QMSP 601, Deviation Request Procedures

3.0 Definitions:



4.1 Any part that is determined to be unusable as to form, fit or function is deemed nonconforming, and should be

identified and segregated to prevent unintended use. Identification would include OEM label, bar code label, or

affixed label showing part number, and if possible, the reason of nonconformity.

4.2 Assembly line.

4.2.1 Any part that is suspected as nonconforming is to be marked with a sticker (typically orange dot), and

placed into the Non-conforming material container in the area. An appropriate container would be a basket,

bin, pallet, skid, etc. that is marked as nonconforming area.

4.2.2 Typically the area supervisor (or designee) is responsible for ensuring that all parts identified with an orange

dot are subsequently identified by part number.

4.3 Support area.

4.3.1 Any part that is suspected as nonconforming will be segregated in its container, which should be labeled

with the repairable material tag (typically red). Information should include part number and nature of

nonconformity.

NOTE: Coils of steel/copper/aluminum are typically tagged with Hold Material tag. See 4.7

4.3.2 Basket or container should be moved to the nonconforming area for disposition.

4.4 Material control.

4.4.1 Any material suspected as nonconforming should be identified with a Hold Material tag (typically blue).

See section 4.7 below for more details on blue tag process.

4.4.2 Material control will coordinate with QA to ensure that all related materials (date code, etc.) are located and

labeled.

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4.5 Area supervisor (or designee) is responsible for coordinating the disposition of any materials that accumulates in

nonconforming areas. This disposition should include appropriate persons, such as QA, production and others as

needed. Items should be dispositioned and moved out of the area for resolution, such as scrap, rework, return to

vendor, etc. on a regular basis (typically daily if time or situation allows).

4.6 Materials segregated as nonconforming can have the following dispositions:

4.6.1 Scrap. Area supervisor (or designee) should follow scrap procedure as detailed in QMSP 109.

4.6.2 Use As Is. Area supervisor coordinates with QA, material control to ensure that the materials are properly

returned to stock for use. This includes physically moving material to the proper location, and to ensure that

any system transactions are

4.6.3 Return To Vendor. The area supervisor (or designee) will complete a pink Return to Stores ticket (QA-041)

for each container. They will then arrange for material to be moved to the QA receiving area for further

processing.

4.6.4 Rework/Repair. The area supervisor (or designee) will move the material back to the appropriate area for

rework, and will confirm with the area supervisor the rework plan.

4.7 If after disposition any material in any area needs to be put on longer term hold pending further investigation, the

Hold Material tag (Blue tag – QA-007) will be used. QA representative (usually QA Auditor of area) is responsible

for initiating and tagging material as follows.

4.7.1 The material is properly tagged with Hold Material Tag (blue tag). The Blue tag is to be affixed to the

basket, cage or container as applicable.

4.7.2 A MRR report is initiated (in Material Review Database). Highlighted fields indicate mandatory

information; all other fields should be completed as needed. Hold Material Tag numbers must be recorded

on the MRR form.

4.7.3 The inventory system is updated to reflect material status as “On Hold” (typically in INSP in Oracle).

4.7.4 If the suspect material has already been installed into production units, the QA investigation will determine

whether a Stop Shipment is needed to prevent nonconforming parts from being shipped. If so, QA will

initiate a Stop Shipment following QMSP 112. The stop shipment number should be entered onto the MRR

form.

4.7.5 If an investigation is necessary to determine the root cause of the nonconformity a CAR may be issued

following the guidelines established in QMSP 102. The CAR number should be entered onto the MRR form.

4.7.6 After the disposition has been authorized by all appropriate personnel, all blue tags must be returned to a

member of the Quality Department.

4.7.7 All products having a scrap or sort disposition must account for scrapped product on a scrap ticket the

guidelines established in QMSP 109.

4.7.8 QA representative is responsible for ensuring disposition of hold material is completed, and will close the

MRR by signing form (typically electronic signature). They will then close in the MRR database.


5.1 Production is responsible for the proper identification and segregation of any suspected nonconforming material, and

alerting QA for chronic or larger scale issues.

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Applicable to:


5.2 Quality Department is responsible for coordinating appropriate discussions, leading to the disposition of

nonconforming material.

5.3 Quality Department is responsible for the application of the hold process, including ensuring system transactions are

completed when necessary for proper inventory tracking and control.

6.0 Quality Records

6.1 MRR Form QA-6.5.3.1

6.2 MRR Database

6.3 Stop Shipment Form QA-030

6.4 Stop Shipment Log QA-030A

6.5 Scrap Tickets QA-043



01 Revised entire procedure 2/19/15

02 General re-write to include Assembly line process 8/17/15

03 Added NOTE to 4.3.1 9/30/15

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Calibration and Control of Inspection,

Measuring, and Test Equipment D. Presley 01 1 of 3


J. Jelks 8/12/16 QMSP 105

Applicable to:


1.0 Purpose:

1.1 To establish the requirement for controlling the accuracy of inspection, measuring, and test equipment and

measurement standards so as to assure that products designed and delivered to the customer conform to specified

requirements.

1.2 This procedure applies to all inspection, measuring, and test equipment that is owned by Rheem, on loan to Rheem,

or owned by employees of Rheem.

2.0 References:

2.1 None

3.0 Definitions:



4.1 All inspection, measuring, and test equipment instruments and devices used to determine an item’s conformances to

specified requirements are to be calibrated. This calibration is to occur at regularly scheduled intervals determined

on the basis of stability, purpose, and usage, or sooner if there is some reason to believe that the instrument or device

needs recalibration. Anyone placing these items into service is responsible for notifying the Quality Assurance

Department to have these items calibrated prior to use.

4.2 All inspection, measuring, and test equipment devices will be calibrated to working measurement standards or

transfer measurement standards and these in turn calibrated to reference measurement standards, which are calibrated

and certified, by the National Institute of Standards and Technology.

4.3 Records are to be maintained that identify each item of inspection, measuring, and test equipment and each

measurement standard and list and date each instance of calibration. The records are to be able to demonstrate

traceability of the calibration work to the National Institute of Standards and Technology.

4.4 Establish a calibration control and recall system for assuring that inspection, measuring, and test equipment devices

and measurement standards are calibrated, and that this is done at intervals that assure their accuracy and for

indicating in advance for each device and standard the date when it is next due to be calibrated.

4.5 Each item of inspection, measuring, and test equipment and measurement standards is to be marked showing the date

of the most recent calibration, the identification of the Technician who performed the calibration, and the date when

the next calibration is scheduled. If the item is too small for this type of marking, adjacent information or a smaller

identifying mark is to be used which is keyed to independently maintained records that cite the same data.

4.6 Inspectors and technicians cannot accept measurement values obtained on inspection, measuring, and test equipment

that have exceeded calibration due dates.

4.7 Inspection, measuring, and test equipment instruments and devices cannot be calibrated with measurement standards

that have exceeded calibration due dates.

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Applicable to:


4.8 Employee-owned measuring equipment can be used for product acceptance measurements only if they are calibrated

by the Company on a regularly scheduled basis.

4.9 The environment where inspection, measuring, and test equipment is used must be controlled to the extent necessary

to assure required accuracy.

4.10 The Quality Assurance Department is responsible for selection and acquisition of commercial inspection, measuring,

and test equipment calibration and/or repair work.

4.11 The Quality Assurance Department is responsible for securing calibration job instructions for all commercial

inspection, measuring, and test equipment that has been procured.

4.12 The Plant Engineering Department is responsible for providing the Quality Assurance Department with calibration

job instructions for Company designed inspection, measuring, and test equipment.

4.13 All new, reworked, repaired, or modified inspection, measuring, and test equipment instruments and devices are to be

examined, and when proven acceptable, certified.

4.14 The Quality Assurance Department will determine the characteristics to be inspected on each piece of inspection,

measuring, and test instrument. Quality Assurance will also determine the method of checking and action required in

case of nonconformity.

4.15 The Quality Assurance Department is responsible and has the authority for disposition and corrective action when

inspection, measuring, and test equipment is found to be out of calibration, mis-used, dropped, or otherwise

suspected of being out of calibration.

4.16 In the event that an instrument is found to be out of calibration after comparing to the measurement standard, the

following steps should occur:

1. Issue Stop Notice For Calibration (QA-0378) for instrument.

2. Tag instrument “Out of Service”

4.16.1 Validation of prior production quality and recalibration will be documented.

4.17 The Quality Assurance Department will maintain a listing of commercial and company designed inspection,

measuring, and test equipment and standards that have been certified.

4.18 The Quality Assurance Department will be responsible for procuring and maintaining all measurement standards

required to support product measurement requirements.

4.19 The Quality Assurance Department will be responsible for developing interim measurement standards in those

instances where reference measurement standards are not yet established.

4.20 In the event an instrument is not returned to QA for calibration by the due date the following steps should occur:

1. Issue a Calibration Recall Notice (QA-0423) for the instrument to Focus Factory Manager and Quality

Engineer responsible for that Focus Factory.

2. Disposition instruments as directed by Focus Factory Manager on Calibration Recall Notice in the

database.


5.1 The Quality Assurance Department Manager is responsible for conformance to this procedure.

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Applicable to:



6.1 Calibration and Control Data System

6.2 Out of Service (QA-00128)

6.3 Stop Notice For Calibration (QA-0378)

6.4 Calibration Recall Notice (QA-0423)




01 Reviewed for accuracy; no changes 8/12/16

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Quality Management System Audit M. McMillen 1 1 of 2


D. Presley 9/10/15 QMSP 106

Applicable to:


1.0 Purpose:

1.1 The purpose of this procedure is to establish the requirements for performing an internal Quality System Audit to

ensure that Rheem’s Quality Management System, as documented is being enforced to provide control of product

quality.

2.0 References:

2.1 Quality Management System Procedure 102, Corrective and Preventive Action Report

2.2 QA-A-100 Audit Form and Questionnaire

2.3 QA-A-99 – Quality Management System Audit Summary (QA-A-99)

3.0 Definitions:



4.1 Internal System Audits shall be scheduled on the basis of the status and importance of the activity to be audited.

4.1.1 Audit schedules will be determined as early in the year as possible, but generally by the end of the first

quarter of the year.

4.1.2 Audits will typically be scheduled in the Reliance system.

4.2 The Quality System Audit will be performed using QA-A-100 audit questionnaire and form.

4.3 The Quality System Audit team will be appointed by the Manager of Quality Assurance. The Auditors will be

qualified based on various American Society for Quality Certifications, or ISO 9000 Auditor Training, or on the job

Audit Training.

4.3.1 A qualified 3rd

party auditor can be used for the purpose of conducting internal audits.

4.3.2 Auditors will not be assigned to audit their own areas of responsibility.

4.4 The Auditor will audit the practices of the department assigned to be audited to determine if they are consistent with

the policies, procedures, and documentation. Evidence of compliance must be provided in a reasonably short period

of time or the information will be classified unavailable.

4.5 The Auditor will write up each discrepancy as it is found including the precise details required to track back to the

specific finding and document that are in conflict.

4.6 The Auditor will orally review the findings with the responsible parties prior to leaving an area.

4.7 A Post-Audit Review of all observations is required with the Department Manager.

4.8 Corrective and Preventive Action Report Form (CAR-001) will be issued for findings (if applicable) and

administered per QMSP 102.

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Quality Management System Audit M. McMillen 1 2 of 2



Applicable to:


4.9 The Quality Assurance Manager will submit as required the audit findings to the appropriate members of Rheem’s

senior management.

4.10 In the event that an immediate action must be taken to address a safety hazard or serious product problem, the

operation will be stopped and the findings reported to the department manager or supervisor.


5.1 It is the responsibility of the Quality Assurance Manager to ensure conformance to this procedure.



6.2 Internal Audit Form (QA-A-100)

6.3 QA-A-99 – Quality Management System Audit Summary (QA-A-99)




1 Various revisions (removed 1.2, modified 4.1, 4.3) 9/10/15

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Internal PPAP

(Production Part Approval Process) D. Presley 1 1 of 3



Applicable to:


1.0 Purpose:

1.1 The purpose of this procedure is to ensure conformance to all Engineering Specifications.

1.2 This procedure applies to all new or rebuilt tooling or equipment that produces a component, sub-assembly, or final

assembly. This procedure may also apply to existing or standard tooling, as necessary.

1.2.1 In the case of rebuilt tooling, only the Revised Tooling will require verification.

1.3 This procedure does not apply to Field Tests. However, PPAP Approval must be accomplished prior to the Pilot

Run.

2.0 References:

2.1 Layout Inspection Report – QA-040

2.2 PPAP Approval in Electronic Database

2.3 Try Out Stock Form

2.4 Reports generated from appropriate measuring devices

3.0 Definitions:



4.1 Manufacturing Engineering and/or Supplier initiates the Request for Try Out Stock Form to Manufacturing.

4.2 Manufacturing shall schedule and produce Try Out Stock per request and notify Quality Assurance.

4.3 Quality Assurance shall verify the Try Out Stock and sign the Try Out Stock Form.

4.4 Any Deviation of the Try Out Stock must be approved by Manufacturing Engineering.

4.5 Manufacturing delivers the Try Out Stock to the designated area and contacts Manufacturing Engineering that the

material is ready for pick-up or shipment.

4.6 The Tool or Equipment Supplier shall:

4.6.1 Submit three sample parts.

4.6.1.1 Omitting the 3-part analysis may be granted by the Division Manufacturing Engineering Manager.

4.6.2 Submit a certified print and a complete Rheem Layout Inspection Form. The document must be signed and

dated by the individual that completed the inspection.

4.6.3 It is recommended that measurement tools utilized during the inspection also be noted to assure consistency.

4.6.4 On critical types of tooling or process equipment Rheem will require at a minimum a 1 hour run-off at the

Supplier’s site. Process potential studies will be conducted on control characteristics.

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Internal PPAP




Applicable to:


4.7 Quality Assurance, or Designee, will verify the accuracy of the Supplier’s measurements and note any discrepancies.

Analysis of 3-part samples may be done by any plant within the Division.

4.7.1 If no discrepancies exist, and the Manufacturing Engineer has satisfied safety, OSHA, construction,

electrical codes, etc., the tool or equipment is approved for shipment.

4.7.2 If discrepancies exist, a disposition must be obtained jointly by Manufacturing Engineer, Project Engineer,

and/or Quality Assurance to determine if the discrepancy is acceptable or not. If acceptable, the

Engineering Specification must be updated to conform to the part. Prior to updating a specification, a

Deviation Request must accompany the discrepant drawing for production to continue.

4.7.3 If resubmittal is necessary, unless otherwise warranted, it shall be for discrepant dimension only.

4.8 On critical tooling and process equipment, Manufacturing must perform an on site study of a minimum of 30 parts

upon receipt of the tool or equipment. Quantity requirements may be different for automated processes, to be

established prior to issue of Rheem Purchase Order.

4.9 When conducting a PPAP, the Quality Assurance Department will layout 5 parts. In the event that existing

programmable Rheem standard tooling requires revision a 1 piece will have a layout. Process potential will be

established for all control characteristics using a statistically valid sample size. A Cpk index of 1.33 or greater is

acceptable.

4.9.1 If no discrepancies exist, PPAP Approval is granted.

4.9.2 Same as 4.7.2

4.9.3 All results will be recorded using Reliance PPAP and Layout Inspection Form or reports generated from

appropriate measuring devices.

4.10 If an Engineering Specification revision is required and cannot be completed before initial production, a Deviation

may be granted for no longer than 2 months.

4.11 Final payment is contingent upon approval, unless otherwise specified in the terms of the Purchase Order.

4.12 Final approval is the responsibility of the person or designator of the person that signs the Purchase Order.

4.13 Final approval, without PPAP Approval, must be granted by the Vice President of Operations.


5.1 Quality Assurance is responsible to ensure this procedure is being complied with.


6.1 PPAP Approval in Electronic Database

6.2 Layout Inspection Report (QA-040)

6.3 Reports generated from appropriate measuring devices

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Internal PPAP




Applicable to:




1 Change title from FAI to Internal PPAP

Replace all verbiage from FAI to PPAP

Remove references to CAR/PAR

12/01/15

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Production Part Approval Process

(PPAP) D. Presley 05 1 of 5



Applicable to:


1.0 Purpose:

1.1 To establish a procedure for the submittal of a sample of initial purchased parts (new or revised) from a Supplier for

approval prior to Rheem’s production usage.

1.1.1 To assure that purchased components and Rheem Engineering Specifications are in agreement prior to

shipment of production quantities.

1.2 This procedure applies to all purchased parts used by Rheem that will become part of an end item shipped to a

customer. Purchase parts excluded from this PPAP procedure include: literature, paint, chemicals, tape, strapping,

and off the shelf items that would be purchased at a general retail store. Exceptions to the above exclusion note can

be requested by Quality when deemed necessary. The submittal of a sample of PPAP parts may be required when:

1.2.1 R&D Engineering releases a new purchased part.

1.2.2 R&D Engineering revises an existing purchased part.

1.2.3 Purchasing selects a new Supplier for a part.

1.2.4 The Supplier changes his manufacturing site.

1.2.5 The Supplier makes a significant process and/or material change.

1.2.6 The Supplier purchases new tooling, modifies existing tooling, or makes significant repairs on existing

tooling.

1.2.7 A part has not been used for 3 years.

1.3 This procedure does not apply to Field Tests. However, PPAP must be accomplished prior to the Pilot Run.

2.0 References:


2.2 Corrective and Preventive Action Report - CAR-001

2.3 Reliance.

3.0 Definitions:


3.2 See Section 1000, Glossary, for PPAP.


4.1 R&D Engineering

4.1.1 Establish control characteristics on new purchased part drawings before submitting them to the Purchasing

Department.

4.1.2 Request assistance from the Supplier and the Quality Assurance Department, when required, to determine

control characteristics.

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Applicable to:


4.1.3 Review any discrepancies in the sample of PPAP parts and determine if the Engineering drawing

should be changed or if the Supplier will have to modify the process.

4.1.4 In the event that a revision to an existing purchased part is necessary, R&D will notify Purchasing in

advance should a PPAP be required. The Division Buyer or the designee will sign all ECNs affecting

purchased components prior to releasing the ECN.

4.1.5 Should R&D require additional testing as part of the PPAP, this should be communicated to

Purchasing. Results of subsequent testing will be documented by Quality Assurance.

4.2 PPAP Coordination

PPAP TYPE Initiates PPAP in Reliance

ECN Projects Division Quality

ECN Maintenance Division Quality

Supplier change/Alternate supplier Procurement Representative

Supplier Initiated PPAP Supplier

Others Division Quality

4.2.1 The Procurement or Division Quality Departments will coordinate and plan with other departments as

required establishing Production Part Approval Process (PPAP) submittal dates to allow sufficient time

for Rheem Manufacturing approval before pilot date or production usage.

4.2.1.1 The Purchasing or Division Quality Department will classify purchased parts with a PPAP

designation after the ECN release. PPAP designation can include:

Y – Is Required

W- Waived

F – Family

NR – No Requirements

4.2.1.2 A representative of the Division Purchasing Department will sign all ECNs pertaining to

purchased parts. If the ECN has no purchased parts a Purchasing representative is not

required to review or sign the ECN.

4.2.1.3 A copy of the Engineering Drawing with the control characteristics identified will be sent to

the Supplier through Reliance.

4.2.1.4 Purchasing may request a waiver of the PPAP. This must be sanctioned by the Plant Quality

Engineer or Plant Manager of Quality Assurance.

4.2.2 Submit PPAP request through Reliance to the Supplier will include the following unless otherwise

noted in the PPAP requirements:

4.2.2.1 Submit three production grade parts for PPAP.

4.2.2.2 Submit a Rheem certified drawing showing that all characteristics of three parts have been

measured and recorded.

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Applicable to:


4.2.2.3 Submit a control plan defining the inspection plan for all characteristics for the part or family

of parts submitted.

4.2.2.4 Submit a process capability study on each control characteristic noted on the drawing. Cpk

must be 1.33 or greater as determined from a statistically valid sample size of at least 30 parts.

4.2.2.5 Require that the Supplier ship the sample parts as one complete package to the Quality

Assurance Department.

4.2.2.6 Require that the above package be marked externally with a Production Sample Label.

4.2.3 The sample parts and documentation package as noted in 4.2.2.5 will be sent to the Quality Assurance

Department of the plant that is identified as the primary.

4.2.4 Review all discrepancies noted on the sample PPAP parts and assist in the coordinating of any drawing

changes required between R&D Engineering, the Quality Assurance Department, and the Supplier.

4.3 Plant Quality Assurance

4.3.1 Record date when sample PPAP parts and documentation are received.

4.3.2 Review in Reliance to assure that:

4.3.2.1 Correct numbers of sample PPAP parts were received.

4.3.2.2 Process capability studies are statistically valid with Cpk of 1.33 or greater for boated

dimensions.

4.3.2.3 Control plans have been submitted for all characteristics.

4.3.2.4 A certified drawing is received and all characteristics have been measured and recorded.

4.3.2.5 The absence, legibility, or any other deficiency noted in the items listed in the Section 4.3.2

may be justification for rejection.

4.3.3 Perform a lay-out inspection of PPAP part using the following guidelines:

4.3.3.1 New part/new tool/new manufacturing site/new source – perform a complete lay-out

inspection on one PPAP sample part checking all characteristics shown on the Engineering

drawing and/or specifications.

4.3.3.2 Revised part/modified or repaired tooling/process changes – inspect those characteristics that

have been directly or indirectly affected by the change on one of the sample parts.

4.3.4 Any drawing characteristic found to be out of tolerance, or other part discrepancies will be noted in

Reliance PPAP submission and the parts held to be reviewed by Purchasing, R&D Engineering, and

Quality Assurance.

4.3.5 Parts meeting all drawings and documentation requirements will be approved for production usage.

4.3.5.1 The Rheem employee performing the inspection will notate Acceptable, Not Acceptable or

Not Required in the comment section on the PPAP. For any Not Acceptable field a

disposition may be entered by Division Purchasing, R & D Engineering, and Quality

Assurance that will allow for Conditional Approval Drawing Change Required or Conditional

Approval Supplier to Re-submit otherwise the PPAP is Rejected.

4.3.6 The results of PPAP’s will be documented and notification will be made through Reliance.

4.3.7 All PPAP submissions will be kept on Reliance and audited by QA.

4.3.8 Appropriate buyers will be notified by Reliance for further communication and coordination.

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Applicable to:


4.3.9 Notification to the Supplier on the acceptance or rejection status of the sample PPAP parts and /or

documentation will be made through Reliance.

4.3.10 Coordinate the resubmittal of sample PPAP parts and/or documentation from the Supplier when

required.

4.3.10.1 Resubmittal is for discrepant dimensions only.

4.3.11 An approval by any one Plant within the Division will constitute approval for all Division Plants.

4.3.12 An approval of one size part will constitute approval of different size parts of the same family where

control characteristics do not change. A “family of parts” constitutes parts of the same base print

number. Indication should be made on the PPAP Form that approval is for family of parts, when

applicable.


5.1 Quality Assurance is responsible to ensure this procedure is complied with.


6.1 Reliance

6.2 Engineering Change Notice



01 1.2 Deleted: corrugated material, wooden skids, 11/10/10

02 4.2.1.4 Inserted: Plant Quality Engineer or 08/17/11

03 Added 2.3: Reliance

Added 3.2: see Section 1000, Glossary, for PPAP

4.2.2 Inserted: Submit PPAP request through Reliance

Deleted: Submit a Purchase Order

4.2.2.5 Deleted: and documentation

4.2.5 Inserted: through Reliance

4.3.2 Inserted: in Reliance

4.3.4 Inserted: in Reliance PPAP submission

Deleted: on the First Article Approval Form

4.3.5.1 Inserted: notate

Deleted: initial the applicable

Inserted: in the comment section on the PPAP

Deleted: field on the First Article Form

4.3.6 Inserted: through Reliance

4.3.7 Inserted: All First Article submission will be kept on the Reliance and audited by QA

Deleted: A file of completed First Article Approval forms and associated document

will be monitored by Quality Assurance

4.3.8 Inserted: Appropriate buyers will be notified by Reliance

Deleted: Deliver the First Article Approval Form with accompanying data (listing

2/10/14

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Applicable to:


Discrepancies) to the appropriate buyer

6.1 Inserted: Reliance

Deleted: First Article Report (QA-039)

Removed 6.2: Purchase Order

Changed 6.3 to 6.2

04 Moved 4.2.5 to 4.3.1

Moved 4.2.6 to 4.3.2

2/13/14

05 Added 1.2 Exceptions to the above exclusion note

Removed 4.1.2 Purchasing designating PPAP status

Insert table of PPAP responsibilities.

12/01/15

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Scrap Procedure D. Presley 04 1 of 2


M. Brannon 8/19/15 QMSP 109

Applicable to:


1.0 Purpose:

1.1 To establish consistent methods for identifying, quantifying, reporting, and disposing of scrap and defective

production material.

1.2 To remove unfit production material from Inventory Control and Accounting Inventory Records.

2.0 References:

2.1 Pertains only to purchased or manufactured production parts and material of the Air Conditioning Division. It does

not include facilities scrap or any other miscellaneous scrap.

3.0 Definitions:



4.1 All scrap materials, parts, and assemblies shall be accounted for by use of the Scrap Ticket – QA-043.

4.2 Production personnel shall survey accumulated defective production material daily and work in separating scrap from

rework. Production will identify all materials to be scrapped out with the correct part number.

4.3 If parts are to be scrapped out, the responsible Area Supervisor, or Designee will confirm proper part identification of

each part number and quantity to be scrapped using the Scrap Ticket.

If parts were red tagged previously and it is subsequently determined that the parts are not repairable, these parts will

then be identified as scrap and accounted for on the Scrap Ticket.

4.4 Before sheet metal parts can be placed in the scrap bin at the location the parts have been identified, the responsible

Area Supervisor, or Designee must complete the Scrap Ticket and then spray the parts to be scrapped with orange

paint for visibility. The parts to be scrapped can then be loaded into the scrap bin. All scrapped parts must be

accounted for and identified. Exceptions to painting scrapped metal parts will be allowed for obsolescence,

Engineering Revisions, etc…

It is the responsibility of Production and Material Control to assure proper and accurate accounting for all scrap.

Production Supervision will continually monitor parts and assemblies isolated for scrap assuring that good judgement

is used and that serviceable or reworkable parts do not become a part of the scrap program.

4.5 The Scrap Tickets will be completed on a daily basis with end distribution to QA Department for retention.

4.6 In the event that material is determined to be obsolete the following will occur:

4.6.1 Provide a written request to the Plant Controller describing the proposed obsolete material with quantities,

part numbers, and other details supporting the proposed obsolete scrap.

4.6.2 Do not scrap the material.

4.6.3 Plant Controller will return documentation back to person who originated requested with disposition of

material with supporting signatures.

4.6.4 The material can then be disposed of and logged onto a Scrap Ticket (QA-043) under Reason Code 56.

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Scrap Procedure D. Presley 04 2 of 2



Applicable to:



5.1 It is the responsibility of the Quality Assurance Department to verify compliance to the procedure.

5.2 The responsible Area Supervisor or Designee will keypunch all scrap tickets.

5.3 Accounting will run Weekly and Monthly listings of scrap by Department, as required.

5.4 Accounting will assist all Departments with assistance for special scrap reports.


6.1 Scrap Ticket (QA-043)



01 5.2 Inserted: or designee 08/16/13

02 4.6.4 Replaced: Code 13 with Code 56

5.3 and 5.4 Replaced: Information Technology with Accounting

03/05/14

03 4.5 Replaced: Material Control with QA

5.2 Replaced: Material Control with Quality Assurance

9/04/14

04 Reviewed for accuracy 8/19/15

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Data Acquisition Network R. Werschky 02 1 of 2



Applicable to:


1.0 Purpose:

1.1 The purpose of this procedure is to establish the guidelines for the use of the Quality Assurance Data Acquisition

Network.

1.2 This procedure applies to all assembly lines supported by the Data Acquisition Network.

2.0 References:

2.1 Defect Summary Printouts

3.0 Definitions:



4.1 This procedure established the use and control for the Data Acquisition Network.

4.2 The type of data collected to ensure acceptance of product and the records maintained for the acceptance are:

4.2.1 Model Number (Bar Code Scanner)

4.2.2 Serial Number (Bar Code Scanner)

4.2.3 Inspector Number (Bar Code Scanner or Touchscreen)

4.2.4 Defects (Touchscreen)

4.2.5 Acceptance (Bar Code Scanner or Touchscreen)

4.2.6 Date and Time Stamp (Computer System Automatic)

4.3 The system will track the following:

4.3.1 Number of Units Inspected

4.3.2 Number of Units Defective

4.3.3 Percentage of Units Defective

4.3.4 Defect Listing

4.3.5 Defect Summary By Problem and Location

4.3.6 Units in Transit

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Data Acquisition Network R. Werschky 02 2 of 2



Applicable to:


4.4 The data collected can be accessed for real time information by the Production Supervisor so that positive measures

may be taken to correct any defects noted.

4.5 This is a secure system; access can only be obtained by a password entry. All passwords are issued by the Quality

Assurance Department or line assignee.

4.6 Any major changes to the system must be approved by Manufacturing Engineering, Quality Assurance Department,

and Information Technology Department.

4.7 Records of any major changes will be maintained by the Supplier of the Data Acquisition System.


5.1 It is the responsibility of Production to ensure the Data Acquisition System is used.

5.2 Quality Assurance will audit per QMSP 106 to ensure compliance to this procedure.

5.3 Plant Engineering and Information Technology will assist as required to maintain the systems.


6.1 Defective Summary Printouts.

6.2 Archive Data and File Server



01 4.6 Inserted: major 8/03/11

4.7 Inserted: major Deleted: Information Technology Department. 8/03/11

Inserted: Supplier of the Data Acquisition System.

02 4.3.7 Deleted: Inspector Activity Report 7/11/13

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Supplier Assessment J. Jelks 03 1 of 2


J. White 9/30/16 QMSP 111

Applicable to:


1.0 Purpose:

1.1 The purpose of this procedure is to describe the method for selecting candidate Suppliers and subcontractors of

material used in deliverable products and services. This is a means of gathering information relative to a Supplier’s

capability to comply with Rheem’s Quality Requirements.

1.2 This procedure applies to all potential O. E. M. Suppliers and candidates for major levels of procurement activity.

1.3 This procedure does not apply for Field Testing. However, for Pilot Runs, this procedure must be complied with.

1.4 All Suppliers added to the “Approved Supplier List” prior to this procedure were by the Grandfather Clause.

2.0 References:

2.1 Quality Management System Procedure 500, Purchasing Supplier Control

2.2 Rheem Manufacturing Company Supplier Quality Manual

3.0 Definitions:



4.1 Candidate Suppliers will be requested to complete the Supplier Company Profile and Supplier Quality Questionnaire

via Reliance per the Supplier Quality Manual (SQM).

4.1.1 Based on that information, SQM dictates the next steps in Section II, 4.3.


5.1 It is the responsibility of the Quality Assurance Department to ensure conformance to this procedure.


6.1 Supplier Self-Assessment (QA Form 5.1.2-2A – 5.1.2–2E)



01 4.1.4 A Inserted: Supplier Self-Assessment will not be required for Suppliers that

have been approved by the Rheem Water Heater Division. The Purchasing

Department must supply the Plant Quality Assurance Manager or his

representative with the Rheem Water Heater Supplier Approval Form for

review. Upon successful review the Supplier and Date completed will be

added to the “Approved Supplier List” by a Purchasing Representative.

5/18/09

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Supplier Assessment J. Jelks 03 2 of 2


J. White 9/30/16 QMSP 111

Applicable to:


02

4.1 Removed: (5.1.2-2A – 5.1.2–2E) Instructions (QA 5.1.2-3A – 5.1.2-3P)

Inserted: Reliance

9/08/14

4.1.1 Removed: (5.1.2-2A – 5.1.2–2E)

03 General re-write: 2.0 removed unnecessary references, added 2.2 Corporate Supplier

Quality Manual: 4.0 removed obsolete content, added references to Corp SQM

9/30/16

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Non-Conforming Materials – Finished Goods M. McMillen 02 1 of 4



Applicable to:


1.0 Purpose:

1.1 To establish a process for the control and disposition of finished goods products suspected of containing a non-

conformance.

1.2 This procedure applies to all finished goods products (both in-house and in the field) manufactured within Rheem

Manufacturing, Air Conditioning Division.

2.0 References:


2.2 Quality Management System Procedure 600, Product Audit Procedures

2.3 Quality Management System Manual Section 16, Control of Nonconforming Product

2.4 See Attachment – Flowchart

3.0 Definitions:



4.1 Any person suspecting that a product contains a non-conformity will immediately report it to his Supervisor and/or

Quality Assurance representative (typically QA Auditor of area). The Supervisor will notify the appropriate QA

representative.

4.2 Quality Assurance (generally the QE and QA Auditor of area) will gather the appropriate information to determine

the nature of the non-conformity, and the possible number of units affected. QA will consult with the appropriate

parties to make the decision of whether a Stop Shipment is warranted.

4.3 Should a Stop Shipment be decided upon, the first step is to contain the Work-In-Process (WIP) in order to prevent

any more non-conforming product from leaving the assembly line.

4.3.1 If the non-conformity stems from an in-house component, QA will collaborate with appropriate in-house

departments (production, materials, support, etc.) to fix, replace or repair the affected component(s) to

restore the product to standard condition. The responsibility of fixing the affected component falls primarily

on the department of origin (if in-house). The Quality Engineer (or designee) will determine whether a

CAR is appropriate for preventing the non-conformance, and if so, will enter into appropriate system (such

as Reliance). The QE (or designee) will note the CAR number on the stop shipment form once created.

4.3.2 If the non-conformity stems from an external source, QA will collaborate with the Supplier QE, planners,

material control to determine if alternate stock is available and how to disposition non-conforming material.

The responsibility of coordinating with the external source would fall to the Supplier QE (or designee), as

would the decision to initiate a SCAR, if applicable. The SQE (or designee) will note the SCAR number on

the stop shipment form once created.

4.4 QA Auditor (or designee) should then determine the appropriate quarantine time period of affected finished goods

products. Considerations can include component date codes, box-out reports, assembly schedules, etc. so that a high

degree of confidence is assured that the non-conforming finished goods is sufficiently bracketed and affected models

are identified.

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Applicable to:


4.5 QA Auditor then initiates the Stop Shipment (form QA-030) and documents the list of suspected finished goods on

the stop shipment list (form QA-030A). The following information (at a minimum) is filled-in at the time of

origination:

4.5.1 Model number/Model name (typically on attached QA-030A)

4.5.2 Department

4.5.3 Date/time

4.5.4 Discrepancy. This should include as much detail of the non-conformity, including discovery mode.

4.5.5 Quality Assurance section information (at bottom)… Quantity, Responsible Dept, etc)

4.5.6 SS Number (typically auto-generated from QA database)

4.6 QA Auditor then distributes the Stop Shipment (and list) to the following departments: Shipping, Sales, Production,

R&D, Division Quality, Marketing, Product Management, DC (distribution center), Plant Management and other

relevant parties.

4.6.1 IF the nature of the non-conformity should impact sales and delivery by more than reasonable, the Corporate

Quality Manager must be copied.

4.6.2 IF the nature of the non-conformity should be determined to be a Critical defect, or a SAFETY issue, the

corporate legal department must be copied. Additional steps are detailed below for non-conforming finished

goods in the field.

4.7 The shipping department supervisor (or designee) checks the list (by serial number) against the inventory system

(such as High-Jump), and any units on the list that show a system status of AVAILABLE are changed to HOLD.

The units that are in TRANSIT (to the DC – distribution center) are subsequently put on HOLD by DC personnel

upon arrival.

4.8 The shipping department supervisor (or designee) then communicates back to the QA Auditor the remaining units

that are presumed to have been shipped to customers, or are now considered non-conforming product in the field

(addressed in section below).

4.9 The QA Auditor notes the product in the field on the QA-030A (typically denoted as “QA-0255” in the Completed

by column). This distinguishes between nonconforming product in-house and nonconforming product in the field.

4.10 Nonconforming Product In-house

4.10.1 QA will coordinate with R&D to determine the appropriate disposition, and will note on the stop shipment

form accordingly in the Authorized Disposition section. QA will sign all sign all stop shipments.

4.10.2 R&D will note any disposition comments on the stop shipment form, and then sign/date if the disposition is

Use As Is, Rework or Repair.

4.10.3 Purchasing (planner) will sign if disposition is Return to Vendor

4.10.4 Accounting will sign if the disposition is Scrap.

4.10.5 As planned rework is completed according to disposition, each unit on the list (QA-030A) is noted as being

OK or BAD, and the person(s) completing the work signs their initials. This includes any unit re-

verification and QA sign-off, if required.

4.10.6 After all the In-house rework is completed (list is completed), QA communicates to shipping supervisor (or

designee) that work is complete, so that the units can be taken off HOLD and made available for sale.

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Applicable to:


4.11 Nonconforming Product In the Field

4.11.1 QA will initiate the QA-0255 form for the units that are in the field. Relevant information includes Stop

Shipment Number, Date, and Number of units.

4.11.2 QA will distribute the form (and the list of units with model number and serial number), gathering the

signatures of R&D, Service, Marketing, Ordering Service, and then QA (typically QE). Generally, Service

is gathered first, and the disposition and comments are noted then for subsequent signees to see and agree to.

Any discrepancies or issues should be resolved as quickly as possible and noted on the form.

4.11.3 IF the nonconformity is deemed a Critical defect, or a SAFETY issue, QA Manager (or designee) is

responsible for convening R&D, Division Quality Manager, Product Manager and other appropriate parties

to ensure all actions are agreed to. The Product Management or Supplier Group Manager, with the

recommendation from the Division President and Vice President of R&D, shall notify the proper Corporate

Law Department. Also, as appropriate, notification will be made to other groups such as U.L., AGA, and/or

the component manufacturer.

4.11.4 For all other dispositions, Product Support Group is responsible for developing appropriate Field Service

Note.

4.11.5 Product Support Group then locates each unit on the list, and coordinates the required action.

4.11.6 Product Support Group is responsible for monitoring progress of field repairs.


5.1 Quality Assurance has the overall responsibility for compliance of this procedure.

5.2 The Quality Assurance Manager or Designee of the affected Plant(s) have the responsibility for obtaining the model,

quantities, serial numbers, and date codes of suspect units that have been shipped.

5.2.1 National Order Center will identify the customers that receive suspect units.

5.3 The Production Department will provide the required manpower, space and equipment to perform reinspection,

rework, and recarton as required.

5.4 The Purchasing Department will be responsible for maintaining a stock of labels used for the identification of

reinspected units.

5.5 The Division Marketing Group has the responsibility of making deliberation concerning major/critical defects that

are in the field.

5.6 The Finished Goods Warehouse Department has the responsibility to quarantine the suspect units in the Warehouse

Management System.

5.7 The Product Management and Support Group are responsible for coordination of “Field Repair”.

5.8 The National Order Department is responsible for coordination of "Field Recall".


6.1 Stop Shipment Notice (QA-030)

6.2 Stop Shipment Form (QA-030A)

6.3 Non-Conforming Products In The Field (QA-0255)

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Applicable to:





01 4.15 Deleted: Milledgeville Plant will Fax the form to Division R&D. 10/21/09

02 General revision to reflect current practices 7/1/15

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QMSP 112 FLOW CHART

Quality AssuranceNotified of

Non-Conformance

IFUseAs Is

QualityAssurance

CloseAndFile

QualityAssuranceVerification

ShipAcceptableProducts

ShippedNon Conforming

Product

QualityAssurance

InitiatesForm

QA.0255

R & DEngineer

ForComments

MarketingDepartment

ForDisposition

IFRepair

InField

IFRecall

Product Management and Support

GroupQualityAssurance

Documentation

NotifyAppropriate

Management

NationalOrderCenter

QualityAssurance

DocumentationNotifyAppropriate

Management

CustomerSatisfaction

Sales

QMSP-112 Flow Chart Attachment Rev. 04

SuspectUnits

Identified

QA VerballyContacts

ProductionSupervisor QA Writes

StopShipment

QA HasWarehouseSupervisorSign StopShipment

WarehouseSupervisor

QuarantinesUnits on Stop

Shipment

QA DistributesStop Shipment

Notice

QualityAssuranceVerification

Use As Is

Rework

Repair

Sort

Scrap

RTV

ProductionReworks Unitsand Identifies

With Pink Card

Units onStop Shipment

Released

Units ShippedBack to Supplier

for Rework

Units Recordedon Scrap FormAnd Scraped

ProductionRepairs Unitsand Identifies

With Pink Card

ProductionSorts Units

and IdentifiesWith Pink Card

WarehouseSupervision

De-QuarantinesAs Units areReworked

ProductionCompletes

Stop ShipmentForm and

Returns To QA

QA IssuesCompleted

Stop Shipment

Warehouse SupervisionRetains Stop Shipment

and Verifies Dispositionsof Returned Units

QA VerballyContacts

WarehousePersonnel

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Document Control D. Presley 02 1 of 2



Applicable to:


1.0 Purpose:

1.1 To establish a procedure to insure control of all documents that can affect the quality of Rheem Manufacturing, Air

Conditioning Division's Quality System.

2.0 References:

2.1 References: NONE

3.0 Definitions:



4.1 Quality Assurance will insure that all appropriate documents pertaining to the quality of a product will be available

at all locations essential to the function of the Quality System.

4.2 The management and supervision will insure that all current documentation is available covering all aspects of work

carried out within the department where the lack of such documentation could affect the performance of the

department or the individuals within it, or the quality of the product.

4.2.1 In some support areas, non-controlled documents can be identified as “Reference Only”, which will allow

dated, hand-written notes that are relevant to the production process. These notes are superseded by

controlled documents that accompany them.

4.3 Quality Assurance will audit to insure that all obsolete documents are promptly removed from all points of issue or

use.

4.3.1 The approving authority will maintain a copy of documents and current revision level to insure that only

the most current document is in use within the system.

4.3.2 Quality Assurance will audit to insure the latest revision is in use.

4.4 All documents prior to release must be dated, reviewed, and approved by the Manager or his appointed

representative and must bared the signature of the approving authority.

4.4.1 Control Plans that are electronically released will have a master copy that bares the signature of the

approving authority.

4.5 All changes and revisions of documents must be reviewed and approved by the same function or department that

performed the original review and approval.

4.5.1 QMSM and QMSP documents must be reviewed at a minimum every 3 years to ensure relevance.

4.5.2 Other documents, such as control plans, work instructions, and other reference material will be reviewed as

needed.

4.6 It is required that all pertinent background information upon which to base a decision and approval after review of

submitted documents be supplied to the approving authority.

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Document Control D. Presley 02 2 of 2



Applicable to:


4.7 Where practical, the nature of the changes to any Quality Systems document will be recorded and retained for a

minimum of 3 years.

4.8 All documents are reissued after incorporation of any revision.

DOCUMENT CONTROL - EXTERNAL ORIGIN

4.9 R&D is responsible for the control of applicable documents of external origin. Control shall entail as a minimum

effort the following:

- Control of an applicable standard type will be assigned to an individual within R&D.

- The controlling individual(s) are responsible for maintaining current revisions.

- Distributed copies will be distinguished as such.

- Obsolete documents will be retained for a period of time as specified in the corporate retention standard.


5.1 It is the responsibility of the Quality Assurance Manager to insure compliance to this procedure.


6.1 Internal Audit Form (QA-A-100)




01 Added 4.2.1 “In some support areas, non-controlled documents can be identified as

“Reference Only”, which will allow dated, hand-written notes that are relevant to the

production process. These notes are superseded by controlled documents that accompany

them.”

Added 4.5.1 “Each document must be reviewed at a minimum every 3 years to ensure

relevance.”

Removed 4.9 “Obsolete documents required to support Production activities will be

distinguished as obsolete. The individual issuing an obsolete document will be

responsible for complying with this procedure.”

10/27/14

02 Modified 4.5.1 to specify QMSM and QMSP

Added 4.5.2 specifying other reference material to be reviewed as needed

7/1/15

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Quality Records D. Presley 01 1 of 2



Applicable to:


1.0 Purpose:

1.1 The purpose of this procedure is to establish the control of all records associated with the quality and acceptance of

any product produced by Rheem Manufacturing, Air Conditioning Division.

2.0 References:

2.1 None

3.0 Definitions:



4.1 All Quality Records will be retained on file for a minimum of (3) years. As disposal becomes necessary, written

quality records will be shredded or discarded. Quality records stored electronically will be deleted as required.

4.2 Inspection Reports, Process Audits, Control Charts, etc are turned in to Quality Assurance. These documents are

filed in the Quality Records area(s). Files are identified by date(s) and/or subject for easy access and disposal as

required.

4.2.1 Reports can be stored in the Receiving Inspection area prior to off-site storage. All documents (storage

containers) need to be legible and readily identifiable.

4.3 Typical retention periods cited below:

RECORD OWNER (Dept) STORAGE LOCATION RETENTION PERIOD DISPOSAL METHOD

Production Logs Production QA 3 or more years Scrap

PPAP QA Reliance Life of the part Electronic Copy Kept on File

QA Inspector Daily QA QA 3 years Scrap

Box Audits QA QA 3 or more years Scrap

Material Review (MRR) QA QA database 3 or more years Electronic Copy Kept on File

Stop Shipment QA QA database 3 or more years Electronic Copy Kept on File

Deviation QA Reliance 3 or more years Electronic Copy Kept on File

Press Inspection Logs QA QA 3 years Electronic Copy Kept on File

Acceptance Records QA QA database 3 or more years Electronic Copy Kept on File

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Quality Records D. Presley 01 2 of 2



Applicable to:



5.1 The Quality Assurance Department Manager is responsible for conformance to this procedure.


6.1 None




01 Deletion of Records sections (2.1 – 2.30) listing various QMSP procedures

Addition of 4.3: Retention Policy list

8/12/16

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Final Inspection and Testing R. Werschky 0 Page 1 of 2 Approved by: Effective date: Document No.:


Rheem Air Conditioning Division – Ft. Smith 1.0 Purpose:

1.1 The purpose of this procedure is to establish the requirement for final acceptance and testing of products produced within Rheem Manufacturing, Air Conditioning Division.

1.2 This procedure applies to all products produced within Rheem Manufacturing, Air Conditioning Division.

2.0 References:

2.1 Quality Management System Procedure 102, Corrective and Preventive Action Report 2.2 Quality Management System Procedure 104, Material Review Process Board

3.0 Definitions:



4.1 All final inspection is performed per supplied Control Plans, Test Instructions, and Work Instructions. 4.2 Final acceptance of any end item will be identified by means of an acceptance stamp after all tests have been

successfully passed. 4.3 When acceptance is granted of any end item it shall be recorded by means of the Bar Code Data System where

applicable. 4.4 All inspection points are identified in the Process Flow Chart, and will state the test and/or Inspection Instruction

number to be used at that point. 4.5 All products will be 100% tested in accordance with all agency requirements. 4.6 R&D Engineering will supply to the Quality Assurance Department all Agency Test Requirements. 4.7 Quality Assurance will issue and control all test instruction to the proper test or inspection points.

4.7.1 Only Quality Assurance can make any revisions to test or inspection instructions. 4.8 All Acceptance Records are maintained on file for a period of three (3) years. 4.9 Any discrepancy shall be recorded and dispositioned per QMSP 102 and QMSP 104.




6.1 Bar Code Data System 6.2 Inspection Log 6.3 Data File Server 6.4 Corrective and Preventive Action Report (CAR-001)

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Final Inspection and Testing R. Werschky 0 Page 2 of 2 Approved by: Effective date: Document No.:


Rheem Air Conditioning Division – Ft. Smith 7.0 Revision History:



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Receiving Inspection D. Presley 02 Page 1 of 4



Applicable to:


1.0 Purpose:

1.1 The purpose of this procedure is to define the inspection criteria for inspection of incoming materials received for

use by Rheem Manufacturing, Air Conditioning Division that will become a part of an end item shipped to our

customers.

1.2 This procedure applies to all incoming materials within Rheem Manufacturing, Air Conditioning Division.

2.0 References:

2.1 MRR 6.5.3-1 Material Review Report

2.2 QA-006 Serviceable Material Tag

2.3 QA-007 Hold Material Tag



2.6 Quality Management System Procedure 104, Material Review Process Board

2.7 Quality Management System Procedure 108, First Article Inspection (FAI)

3.0 Definitions:



4.1 Quality Assurance Receiving Inspection will ensure that the following guidelines are followed in the inspection and

acceptance or rejection of all incoming materials.

4.1.1 Quality must be contacted when a shipment of parts from the suppliers noted in 4.2 arrives.

4.1.2 Assure that required measuring and test equipment is available for inspection of materials.

4.1.3 Request assistance from R&D Engineering when functional inspection or tests requirements has not been

established.

4.2 Suppliers will be chosen at the discretion of the Supplier Quality Engineer to have their product inspected per MIL-

STD-105E. These Suppliers will be chosen based on the quality indicators with any three of the four listed:

A. Top Ten Supplier PPM YTD

B. Defect caused line downtime

C. All inventory has to be inspected

D. Repeat Issue

Defect acceptance will be zero (c=o). Inspection will be item specific.

4.2.1 Rheem will use (c=o) on any Supplier as necessary when a problem warrants such inspection.

4.3 All Suppliers except those in 4.2 that supply material will not be inspected at Receiving Inspection unless there is

clear visual evidence of shipping damage or unordinary circumstances.

4.4 Visual inspection will be in accordance with General Inspection Level I and functional testing will be in accordance

with Special Inspection Level S-I, unless otherwise specified.

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Applicable to:


4.5 Level of inspection used in Receiving Inspection will be reject on one defect and accept on zero defects.

4.6 The Receiving Inspector will enter the inspection results of each specific lot of part numbered items from each

Supplier into the Supplier Inspection Log. The inspection results will include the Supplier, part number, part name,

P.O. number, quantity received, sample size, number of defects in the sample, who performed the inspection, and

the results of the inspection. If the lot of material is rejected, the cause for rejection, MRR No., and date will also

be entered.

4.7 The Receiving Inspector will visually, physically and/or functionally inspect each piece of the selected sample to

the extent necessary to insure that the material received meets the requirements established in the Engineering

Drawings, Engineering and customer specifications, and/or Purchase Order.

4.8 The Quality Assurance Manager at his discretion may have any lot of materials received subjected to inspection.

4.8.1 The Quality Assurance Manager or designee may also request the following from any Supplier:

a) A Control Plan defining the inspection plan for control characteristics.

b) A Process Capability Study for each control characteristic.

c) Documented evidence of conformance to a Control Plan and/or Capability Study.

d) Documented evidence of corrective and preventive actions.

4.8.2 Documented of the above requested items will be retained in Quality Assurance.

4.9 Parts and accompanying documentation submitted from Suppliers for "Production Part Approval Process" (PPAP)

will be inspected in accordance with QMSP 108 titled, "Production Part Approval Process". Status and historical

record files will also be maintained on PPAP parts and documentation in accordance with the same QMSP 108.

4.10 If the Receiving Inspector finds the material to be acceptable, he/she will attach a QA Approved Tag to the material

or container and release the material to Stores or to the Assembly Line.

4.11 The Quality Assurance Department will coordinate all nonconforming material with the Supplier for disposition and

corrective action.

4.12 If the material is found to be nonconforming, the Receiving Inspector will perform the following steps:

4.12.1 Complete a MRR and a Hold Material Tag and attach the tag to the nonconforming material.

4.12.2 Issue CAR-001 per QMSP 102, as required.

4.12.3 Insure that the nonconforming material is placed in the Hold Area.

4.12.4 Enter the inspection results into the Supplier Lot History data file.

4.12.5 Ensure inventory transaction is performed.

4.13 The approved disposition from the Material Review Board is Use-As-Is per QMSP 104 the following action will be

complied with.

4.13.1 Remove the Hold Material Tag.

4.13.2 Complete a Serviceable Material Tag noting on the tag the Material Review Report number and attach the

tag to the material or container.

4.13.3 Insure that an inventory adjustment is performed.

4.14 If the approved disposition from the Material Review Board is "Scrap", the Receiving Inspector will perform the

following steps:

4.14.1 Remove the Hold Material Tag.

4.14.2 Spray the parts to be scrapped with orange paint and/or mutilate with a hammer.

4.14.3 Ensure inventory transaction is performed.

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Applicable to:


4.15 Line rejects are defined as the random failure of purchased parts that have been installed or the random occurrence

of purchased parts that cannot be installed. Any number of parts of a specific part number that have been issued to

a using department and are found to be unusable due to fit or function, to the extent that the unused portion has to be

removed and returned to Receiving Inspection, will be handled according to section 4.15.3. A stock check as

appropriate will then be performed to insure that none of the same part numbered items remaining in stock contain

the same deficiency.

4.15.1 The assembly lines will separate and tag defective parts by discrepancy, part number, Supplier, and

quantity before returning to the Receiving Inspection Area. All improperly tagged items will be returned

to the originating assembly line.

4.15.2 Receiving Inspection will make an entry into the Line Reject History data file on all defective purchased

parts returned as line rejects. The entry will include the date, part number, part name, department returned

from, reason for rejection, quantity, and if it is the Supplier or Rheem responsibility.

4.15.3 Receiving Inspection will contact Suppliers who had line rejects for the disposition of parts that are their

responsibility. Rheem responsible line rejects will be dispositioned by Receiving Inspection.

4.15.4 If the disposition is scrap, Receiving Inspection will insure that an inventory adjustment is performed.

4.15.5 All items to be scrapped will be put in the QA Receiving Scrap containers.

4.15.6 If the disposition is "Return to Vendor" (RTV) a "Miscellaneous Shipping Order" (MSO) will be

completed by the Receiving Inspection Department and arrangements made to return the material to the

Supplier.




6.1 Material Hold Tag (QA-007)


6.3 Line Reject Data File

6.4 Material Review Board Log (Form 6.5.3.2)

6.5 MRR Form (Form 6.5.3.1)

6.6 Supplier Inspection Log




01 Deleted: 4.1.a) and 4.1.b) Inserted: 4.1.1 Quality must be contacted when a shipment of

parts from the suppliers noted in 4.2 arrives.

4/20/09

01 4.4 Deleted: Single sampling plans for normal inspection will be used. Inserted: ,unless

otherwise specified.

4/20/09

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Applicable to:


01 4.11 Deleted: The Receiving Inspector will then enter the inspection results into the

Supplier Lot History data file.

4/20/09

01 4.17 Deleted: If the returned items can be traced to a specific lot received, the Supplier Lot

History data file will be corrected to reflect a rejected status.

4/20/09

01 4.17.5 Deleted: After the items have been scrapped, Receiving Inspection will enter the

disposition into the Supplier Line Reject history data file.

4/20/09

01 4.17.7 Deleted: After the items have been shipped, Receiving Inspection will enter the

disposition into the Supplier Line Reject data file.

4/20/09

01 With these revisions the numbering changed from 4.1 thru 4.17.7 4/20/09

01 Inserted: 6.6 Supplier Lot History File 4/20/09

02 General update: removed 4.1.4, 4.15

modified 4.16.6 – removed ‘spray with orange paint’

modified 4.6 verbiage on handling rejected material

changed Supplier Lot History Data file to Supplier Inspection log

updated FAI to PPAP

8/8/16

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Title: Review by: Revision No.: Page:

Quality Assurance Product Audits M. McMillen 1 Page 1 of 1



Applicable to:


1.0 Purpose:

1.1 The purpose of this procedure is to establish the requirements for performing a Quality Assurance Product Audit to

insure that Rheem's work and inspection instructions are being carried out to insure the control of product quality.

1.2 This procedure applies to the audit of all Production Areas.

2.0 References:

2.1 Engineering Drawings

2.2 Model Bill of Material

3.0 Definitions:



4.1 The Quality Assurance Department will audit the Production Assemblies, Fabrication, Testers, and Inspectors in

Production Areas to insure that they are performing the work, tests and inspection in a manner that will comply to

Engineering Drawings, Work Instructions, and Inspections specified.

4.2 Discrepancies will be noted on the Process Audit Form. Quality Engineer will issue correct actions, as necessary, for

repetitive discrepancies or Major findings (per QMSP 102).


5.1 Quality Assurance Manager is responsible for the conformance to this procedure.


6.1 Process Audit





1 Changed title to ‘Product Audit’

Added 2.2 Bill of Material

Changed 4.2 for clarification

10/2/15

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Statistical Techniques R. Werschky 0 Page 1 of 2


R. Turner 4/06/09 QMSP 118

Applicable to:


1.0 Purpose:

1.1 The purpose of this procedure is to establish the requirements for performing various statistical techniques in order to

provide control of product quality.

1.2 This procedure applies to any fabricated component, subassembly, raw material, or finished goods with such R&D

requirements.

2.0 References:

2.1 SPC Chart Usage Instructions WIF-0178.

2.2 Process Capability Study Instructions WIF-0180.

2.3 Product Characteristic Classification EP-1004.

2.4 Gage R&R Study Instruction WIF-0179.

3.0 Definitions:



4.1 Statistical techniques such as Capability Studies, R&R Gage Studies, and SPC charting are used to analyze a process

or its resultant output.

4.2 Product characteristics are classified by R&D to alert Quality Assurance and Manufacturing of required statistical

control.

4.2.1 R&D may use such methods as design and/or process FMEA's to produce the classification and

characteristics.

4.3 A written Control Plan is prepared by Quality Assurance detailing the evaluation method, sample size, frequency of

sample, analysis method, and corrective action to be used in the case of nonconformance.

4.4 Product characteristics denoted as critical (ie boated dimension) are required to have a minimum of 1.33 Cpk.

4.5 Product characteristics denoted as minor will also be monitored utilizing a control plan. No statistical analysis is

required.

4.6 Additional characteristics may be selected by Quality Assurance to monitor for improved Process Control.




6.1 SPC Charts

6.2 Process Capability Data

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Statistical Techniques R. Werschky 0 Page 2 of 2


R. Turner 4/06/09 QMSP 118

Applicable to:





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Rheem Fort Smith Total

Productive Manufacturing J. Gray 01 Page 1 of 2


B. Gahr 10/23/13 QMSP 202

Applicable to:


1.0 Purpose:

1.1 The purpose of this process is to establish the total productive manufacturing procedures that will be followed by all

departments (including Maintenance and Tool and Die) to ensure that all critical production equipment and tooling

are mechanically and electrically capable of producing products that meet design specifications.

2.0 References:

2.1 Reference Document. Total Maintenance System.

2.1.1 Material and Process Substitution Form QA-0130.

2.2 Computer Software

2.2.1 Enterprise Asset Management – Oracle Corporation.

3.0 Definitions:



4.1 It is the policy of this Plant that all equipment and tooling that is of significant value or that has sufficient impact

upon the quality of production shall be incorporated into a Total Productive Manufacturing Program. Specific items

to be included in the program will be determined by each individual plant. The basis of the Program will be a

personal computer network utilizing the software TOTAL MAINTENANCE SYSTEM version 2.3 or higher and

daily inspection sheets maintained in each individual Focus Factory. The emphasis of this program is that it is not

just a "Maintenance or Tool and Die" Program, but rather that it is an all inclusive program that incorporates

equipment Operators, equipment Suppliers, Quality Assurance personnel, and Engineers.

4.2 The Plant Engineer (Facilities), Engineering Department, and Toolroom Foreman will determine which equipment

and tooling will be included into the TPM Program as well as the P.M. Program.

4.3 The Maintenance and Engineering Departments will establish P.M. tasks and frequency, based upon equipment

Supplier's recommendations and previous experience.

4.3.1 The Focus Factory Managers with input from the Maintenance Department will establish and maintain daily

and weekly TPM’s. Monthly TPM’s will be established and maintained where applicable.

4.4 The Foreman will assign specific tasks to the appropriate personnel and ensure their completion.

4.5 The Superintendent will develop forms necessary to record the Operator maintenance.

4.6 The Q.A. Department may route pertinent SPC Charts and/or Capability Studies to the Focus Factory. Data can be

utilized to adjust frequency of TPM and tasks.

4.7 The TMS Software will automatically schedule the next round of P.M. tasks for each piece of equipment.

4.7.1 The individual Focus Factories will schedule and maintain Daily Check Sheets for each piece of equipment

identified by the Superintendent and/or Plant Engineer.

4.8 In the event that it is necessary for the preventive maintenance to be delinquent, this will be documented through a

Process Deviation, QA-0130.

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Rheem Fort Smith Total

Productive Manufacturing J. Gray 01 Page 2 of 2


B. Gahr 10/23/13 QMSP 202

Applicable to:


4.9 In the event that tooling or equipment in the Total Productive Manufacturing (PM) Program is delinquent, it will be

documented in a weekly Delinquency Report. This report will monitor and appropriate action will be taken, as

needed.


5.1 The Plant Engineer, Facilities has responsibility for the equipment portion of the program.

5.1.1 The Plant Engineer, Facilities has responsibility for the tool and die portion of the program.

5.2 The Maintenance and Engineering Departments are responsible for:

5.2.1 Establishing Preventative Maintenance tasks and schedules.

5.2.2 Determining what equipment and which dies shall be included into the P.M. Program (MWI).

5.3 The Maintenance Department is responsible for scheduling the P.M. tasks, printing the P.M. Work Orders, and

closing out all completed Work Orders.

5.4 The Maintenance, Tool and Die Foremen are responsible for assigning the Work Orders to individuals and

supervising the accomplishment of the tasks.

5.4.1 Ensuring the Preventive Maintenance tasks are completed properly and in a timely manner.

5.4.2 Ensuring the Preventive Maintenance personnel and equipment Operators are fully trained and equipped to

perform their assigned task.

5.5 The Production Foremen and Group Coordinators are responsible for assigning specific operator maintenance tasks

to equipment Operators and supervising the accomplishment of the tasks.

5.6 The individual Focus Factory will be responsible for scheduling the Daily Operations Check Sheet, distributing the

Daily Check Sheet, and maintaining all records associated with the Operator’s Daily Check Sheet.


6.1 Enterprise Asset Management – Oracle Corporation.

6.2 PM Records are retained for a period of time as specified in the corporate retention standard.

6.3 Material and Process Substitution (QA-0130)




01 2.2.1 Deleted: Total Maintenance System – Four –Rivers Software Corporation.

Inserted: Enterprise Asset Management – Oracle Corporation .

4.5 Deleted: Focus Factory Managers Inserted: Superintendent

4.7.1 Deleted: Focus Factory Manager and/or Maintenance Manager.

Inserted: Superintendent and/or Plant Engineer.

6.1 Deleted: TMS-Total Maintenance System – Four Rivers Software Corporation.

Inserted: Enterprise Asset Management – Oracle Corporation .

10/23/13

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Routing and Order For Press Parts R. Scott 01 Page 1 of 2


B. Gahr 10/23/13 QMSP 203

Applicable to:


1.0 Purpose:

1.1 To establish a procedure for the control of all sheet metal parts manufactured at Rheem.

1.2 This procedure applies to the Fabrication Departments.

2.0 References:

2.1 R&O Forms stored in Oracle ERP System.

2.2 Material and Process Substitution Form QA-0130.

3.0 Definitions:



4.1 R&D releases a print of a sheet metal part.

4.2 Industrial Engineering writes a preliminary R&O with part number and steel type.

4.3 Industrial Engineering adds calculated blank size and operation order.

4.4 Industrial Engineering enters operations and calculates labor standards.

4.5 Standards entered into Oracle ERP System, R&O and material usage entered into Bills of Materials.

4.6 When dies are received the R&O's are routed back to Industrial Engineering for firm shear size, die numbers, and

operation order verification.

4.7 Only Industrial Engineering is authorized to change an R&O.

4.8 Substitutions for an R&O must be approved by the Operation Supervisor.

4.8.1 When specified press categories are unavailable, parts may be produced in a substitute press for that specific

run only with no documentation required. All other R&O substitutions will be recorded on the Material and

Process Substitution Form QA-0130. Appropriate copies will be distributed by the next working day.

4.9 R&O is maintained for the life of the part.


5.1 Industrial Engineering is responsible for the enforcement of this procedure.


6.1 Press Set-Up Card

6.2 Material and Process Substitution (QA-0130)

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Routing and Order For Press Parts R. Scott 01 Page 2 of 2


B. Gahr 10/23/13 QMSP 203

Applicable to:





01 2.1 Deleted: Main Frame Computer at Rheem-Ft. Smith. Stored by “AE-“ Part Number.

Inserted: Oracle ERP System.

4.5 Deleted: Mainframe Inserted: Oracle ERP System,

10/23/13

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Process Control G. Ruple 01 Page 1 of 2 Approved by: Effective date: Document No.:



1.1 To establish a procedure for the control of products manufactured at Rheem. 1.2 This procedure applies to Production, Industrial Engineering, Quality Assurance, and Research and Development

(R&D).

2.0 References:

2.1 Quality Management System Procedure 203, Routing and Order For Press Parts

3.0 Definitions:



4.1 R&D designs a unit with input from Quality Assurance, Industrial Engineering, Production, Marketing, and other disciplines, as appropriate.

4.2 Industrial Engineering, with input from Production, determines the appropriate processing methods to utilize. 4.3 In order to assure process capability on product dimensions, Quality Assurance will assist Industrial Engineering in

process equipment selection using the appropriate analytical and/or statistical techniques to validate the process. 4.4 Once the equipment has been approved and installed, a Pilot Run involving Industrial Engineering, Quality

Assurance, Production, and R&D will be conducted. 4.5 Based on the results of the Pilot Run, modifications will be made as necessary. 4.6 Quality Assurance and R&D will then determine the Quality Tests necessary to assure continuing process control.

4.6.1 The Industrial Engineering Department will provide Operation/Work Instructions as necessary for process control of equipment.

4.6.2 Production will provide Operator Work Instructions as necessary for process control of assembly operations. 4.7 Quality Assurance will develop the necessary process control documentation as detailed in the pertinent QMSP's (ie.

Document Control, Inspection and Test Records). 4.8 Full production runs begin.


5.1 R&D is responsible for design and proper assembly with input from IE, Production, and Quality Assurance. 5.2 Production Line Layouts and Time Standards will be prepared by the Industrial Engineering Department with input

from Production, Quality Assurance, and R&D, as appropriate. 5.3 Industrial Engineering is responsible for the enforcement of this procedure.

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Process Control G. Ruple 01 Page 2 of 2 Approved by: Effective date: Document No.:


Rheem Air Conditioning Division – Ft. Smith 6.0 Quality Records:

6.1 Data Acquisition and Repairable Material Tag (QA-004) used to track defects.

6.2 Material Hold Tag (QA-007).



0 Initial issue of ISO 9001:2008 4/06/09 01 Deleted: 4.2 4/09/09 01 4.3 Deleted: Based on the layout and design constraints,; Inserted: , with input from

Production, 4/09/09

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Human Resources D. Presley 02 Page 1 of 2


R. Dhone 12/3/15 QMSP 300

Applicable to:


1.0 Purpose:

1.1 The purpose of this procedure is to ensure all employees are verified and documented to be competent in their

specific job assignments on the basis of their education, training, skills and experience.

1.2 This procedure will apply to all departments within Rheem Ft. Smith.

2.0 References:

2.1 Orientation Sheet

2.2 Hazard Communication Training

2.3 Lock/Tagout Training

2.4 Electrical Safety-Related Work Practice Training

2.5 Lift Truck Operator Training

2.6 Hearing Conservation Training

2.7 General Safety Training

2.8 Quality Policy

2.9 Personal Protective Equipment

2.10 Blood Borne Pathogens

2.11 Fall Protection

2.12 Supervisor Accident Investigation

3.0 Definitions:



4.1 Human Resources Department will ensure that competencies are established for all hourly as well as management

personnel.

4.1.1 Competencies shall be on the basis of Education, Training, skills and experience. Job qualifications will be

described on all job descriptions.

4.2 Training Programs will consist of specific requirements in order to safely and efficiently perform particular tasks.

Suppliers or other outside resources will be used to support training as necessary.

4.3 Specialized training (e.g. SPC and Brazing) for skilled jobs will be conducted as required.

4.4 Educational Courses will be made available for jobs requiring Certification. Courses are also made available to

employees for the enhancement of job performance when applicable. Course work may be necessary on employee’s

time.

4.5 Human Resources and Production Supervision will be responsible for new hire orientation concerning safety, quality,

and operations. This information will include, but not be limited to, Orientation Sheets, Quality Policy, General

Safety training and Hazard Communication Training.

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Human Resources D. Presley 02 Page 2 of 2



Applicable to:


4.6 The employee’s supervisor will verify that each of his or her employees meets the competence levels for the assigned

job on the “Hourly Employee Orientation” form, and return the form to HR. Orientation documentation and all

special training, such as fork lift, hearing conversation, webinars and seminars, etc. will e placed in HR’s Training

Access database. However, all work station specific training will be kept at the work station, so supervisory

personnel have 24/7 access to the information.

4.7 Human Resources along with Management will identify additional training needs using job performance objectives.

Additional job specific training will be conducted

4.8 Human Resources along with Management are responsible for determining the effectiveness of training. Evaluations

will be conducted after training to determine performance effectiveness and documented in the Human Resources

Department.

4.9 The Human Resource Generalist shall maintain job descriptions for each individual and training programs for the

facility.


5.1 Conformance with this procedure is the responsibility of the Human Resources Department.

5.1.1 It is the responsibility of all Department Supervisors to ensure compliance with this procedure.


6.1 Human Resource Records




01 Item 4.7:

Removed: The Human Resource Department will verify that each employee, meets

competence levels for the assigned job. All documentation pertaining to the

employee’s competence for the position will be placed in the employees personnel

file.

Inserted: The employee’s supervisor will verify that each of his or her employees

meets the competence levels for the assigned job on the “Hourly Employee

Orientation” form, and return the form to HR. Orientation documentation and all

special training, such as fork lift, hearing conservation, webinars and seminars, etc.

will be placed in HR’s Training Access database. However, all work station specific

training will be kept at the work station, so supervisory personnel have 24/7 access

to the information.

8/15/14

02 Removed 2.2 and 2.10 from References

Moved and reworded 4.6 to new 4.7

Changed 4.9 to Generalist

12/3/15

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Human Resources Record Keeping Procedure D. Presley 01 Page 1 of 5



Applicable to:


1.0 Purpose:

1.1 The purpose of this procedure is to ensure a secure and accurate recording process for employee files; while

maintaining compliance with Rheem’s documentation policies and government regulations.

2.0 References:

2.1 Rheem Manufacturing Company Policy & Procedure Manual Number 1901 Section: Record/Document Retention

Schedule

2.2 View/Request Personnel File Form

2.3 Salaried Termination Checklist

2.4 Hourly Termination Checklist

3.0 Definitions:



4.1 Employee personnel records are maintained in our human resources department. As required by law, some records

pertaining to employees are maintained in separate files relating to medical issues and internal investigations.

4.2 When an employee is hired with Rheem a new personnel and medical file will be created for the employee.

4.3 The file title will include the employee’s last name, first name and clock number.

4.4 Current employee files will be maintained onsite while the employee is actively employed with the company.

4.5 Current employee files will be located in a secure storage area in the plant human resource department.

4.6 Only human resource personnel will be allowed to access the employee files.

4.7 Rheem Manufacturing Salaried, Rheem Fort Smith hourly, Sure Comfort, and RDC employee files will be

maintained separately and labeled as such.

4.8 All files will be stored chronologically by the employee’s last name, first name.

4.9 I-9s will not be included in either of the employee files per government regulation; I-9s will be maintained in two

separate binders for active and inactive employees.

4.10 Performance appraisals are kept separate from the employee files. They are stored in binders per appraisal year in the

HR office.

4.11 Personnel Files and medical files will be maintained separately to comply with government regulations, including

HIPPA. Below is what is to be included in both medical personnel file, and investigation files:

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4.12 Employee Personnel File will include the follow information if applicable to the employee:

4.13 Employment History

Job application

Resume

Education verification

Employment verification

Employment and personal reference checks

Rejection letter

Position job description

Offer letter or employment contract

Emergency contact information

Signed training forms

Checklist from new employee orientation showing topics covered and by whom

Any relocation agreements and documentation

Any contract, written agreement, receipt, or acknowledgment between the employee and the employer (such

as a non-compete agreement, an employment contract, or an agreement relating to a company-provided car),

for example

Life of employment official forms including: requests for promotion, transfer, or internal job applications,

and so forth

Any other documentation related to employment

4.14 Employee Performance Development and Improvement

Employee self-assessments

Records from any formal counseling sessions

Notes on attendance or tardiness

Performance improvement plan documentation

Disciplinary action reports

Employee recognition presented such as certificates, recognition letters, and so forth

Employee formal suggestions and recommendations, organization responses

Training records

Requests for training

Competencies assessments

Training class or session notifications or schedules

Needs assessments signed

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Training expense reports

Complaints from customers or coworkers

4.15 Changes in Employees Personal Status

Change of address, phone number, or emergency contact

Change of name including supporting documentation (such as divorce decree or marriage license)

4.16 Employment Termination Records

Employee resignation letter

Exit interview documentation

COBRA notification

Employment ending checklist

4.17 Employee Medical Files will include the following information if applicable to the employee:

4.18 Medical information

Health insurance application forms

Life insurance application forms

Applications for any other employee benefit that might require medical information

Requests for paid or unpaid medical leaves of absence

Family Medical and Leave Act (FMLA) reports and related paperwork

Physician’s examinations, notes, correspondence, and recommendations

Medically-related excuses for absenteeism or tardiness

Medical job restrictions

Accident and injury reports, including OSHA-required documents

Workers' compensation reports of injury or illness

Any other form or document that contains private medical information about an employee.

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4.19 Once an employee is terminated the human resource department will removed both the personnel and medical file

from the active files directory.

4.20 Terminated employee files are housed onsite for the remainder of the current year.

4.21 In January of the each year the employee terminated files for the prior year will be scanned and sent to Central

Records for storage.

4.22 Medical files and Personnel files will be stored in separate boxes and marked as medical or personnel files termed in

“year of term”

4.23 Each storage box will be marked for destruction (10 years) after the termination per Rheem’s Record/Document

Retention schedule

4.24 Employee Investigation files will include the following information if applicable to the employee:

4.25 Investigation

Litigation documents

Employee Complaints

Litigation interviews or witness interviews

Attorney recommendations

Resolutions

4.26 All employees will have a personnel and a medical file; however, employees may or may not have an investigation

file.

4.27 Access to Employee Personnel Files:

4.27.1 Employees, or their representative, may request access to their basic personnel file. Depending upon the

circumstances, employees may be provided access to records pertaining to internal investigations, with

appropriate redactions to protect the rights of others.

4.27.2 All requests for access to your personnel file must be provided in writing to human resources. Upon receipt

of your written request, human resources will schedule an appointment for you to view your file during

normal office hours. For purposes of this policy, your personnel file includes records related to performance

and training as well as other records used for hiring, promotion and disciplinary decisions. It will not include

any reference checks, medical records or investigation files. Employees are not permitted to remove any

documents from the personnel file but may provide a written response to any document in the personnel file.

Written responses will be attached to the original document in the personnel file.

4.27.3 Employees may request copies of documents in their personnel file. Requests for copies must also be made

in writing to human resources.

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5.1.1 It is the responsibility of all Department Supervisors to ensure compliance with this procedure.





0 Initial Creation of Procedure 2/18/15

01 Minor edit to 4.22 12/3/15

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Human Resources Staffing Procedure D. Presley 01 Page 1 of 6


R. Dhone 02/18/2015 QMSP 302

Applicable to:


1.0 Purpose:

1.1 The purpose of this procedure is to ensure a consistent and timely practice when staffing the production floor.

2.0 References:

2.1 Staffing Timeline Gantt Chart

3.0 Definitions:



4.1 Identifying Staffing Needs through a line rate change

4.1.1 New rates are established

4.1.1.1 Standard hours per unit calculation is made for the number of additional heads in department.

4.1.1.2 Meetings are conducted to align standard rate with budget and production needs.

4.1.1.3 Any department rebalancing is addressed during the staffing meeting.

4.1.2 Needs are communicated to HR and accounting

4.1.2.1 Superintendents email a complete a staffing requirement by classification form to HR and

accounting.

4.1.2.2 Supervisors do not have the authority to request major headcount changes without an approval

from the superintendent.

4.1.2.3 Once the number of additional employees is identified, HR will begin to recruit externally for the

same number of additional employees.

4.1.2.4 At this time, the exact positions required will not be known (general idea based on recent bid

history), so HR will start recruiting externally for the highest qualified general production. The

premise will be during this recruiting effort that the recruited employee may be a bid placed in a

bid positions. The (general idea) will be used also.

4.1.2.5 Once a finalized number of required bid jobs is complete; the bid process starts at least two weeks

prior to the need. When HR bids and awards the positions they will have a noted future move

date.

4.2 Identifying staffing needs through attrition

4.2.1 Employee is moved from their current position due to the bid process.

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Staffing%20Timeline%20Gantt%20Chart.pptx




R. Dhone 02/18/2015 QMSP 302

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4.2.1.1 If the employee’s current job is considered a bid job, it will be placed on the next bid sheet. See

bid process in III.A.

4.2.1.2 If the employee’s current job is not considered a bid job, HR will email the superintendent to

verify replacement.

4.2.1.3 The recruiting process will begin if position is to be replaced.

4.2.1.4 If an employee is missed through the bid system or if production decides to replace at a later date,

production supervisors have the authority to request an additional headcount for day to day

operational reasons.

4.2.2 If an employee quits or is terminated

4.2.2.1 HR emails the termination notice to the termination notification email group

4.2.2.2 Superintendent or supervisor replies all replace or hold on the vacated position

4.2.2.3 If an employee is missed through the attrition process or decided to replace at a later date,

production supervisors have the authority to request an additional headcount for day to day

operational reasons

4.2.3 An opening Occurs when an employee is out for extended leave and placed into F999

4.2.3.1 HR emails the superintendent the employee out on leave and how long the employee will be out

for leave.

4.2.3.2 Superintendent replies all either fill temporarily or hold on the position.

Note: If/when the employee returns to work, they will come back to their previous position and the new

transfer will be moved

4.3 Filling the Staffing Needs

4.3.1 Bid jobs are posted for new open positions. (2 week timeline)

4.3.1.1 Bid jobs are posted on Monday at 10am and taken down on Wed at 10am.

4.3.1.2 Between Wednesday and Friday, HR emails new bids to be posted the following Monday to the

superintendents.

4.3.1.3 Superintendents reply with any changes that should be made before posting.

4.3.1.4 If no reply is made, the bids are considered ok to post on Monday.

4.3.1.5 Status change is made and emailed out by the end of the day on Thursday, for the following

Monday’s changes.

4.3.1.6 Bid positions that were unsuccessful in the first bidding must be posted twice before filling

through force by seniority, temp to perm, or external.

4.3.1.7 If positions are awarded internally through the bid process, the vacated bid position is then posted

the following and steps 1 & 2 are repeated until all vacancies are filled.

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4.3.1.8 Bid positions are defined as Labor Grades 1-9.

4.3.2 Unsuccessful bid process

4.3.2.1 If the bid process turns up no bidders for either new bid positions or currently vacated positions,

the company has the option to:

4.3.2.2 Force lowest qualified PW in plant into bid position (less than a week following Monday)

4.3.2.3 Move temp to permanent (less than a week following Monday if all requirements are met)

4.3.2.4 Hire externally (1-2weeks from order average timeline)

4.3.2.5 Interim “band aide fix” if needed- We can temporarily transfer qualified person to meet

immediate need until a permanent qualified employee is found. (Immediate-following Monday)

4.3.2.6 Note: All three have been utilized at different times. No defined cascade, each option works

better in different scenarios. HR and production will have a joint discussion on the options for

each scenario and decide what will work best at that time.

4.3.3 PW worker positions

4.3.3.1 Employees can use the card process to put in a transfer to an open PW worker position. Regular

bid roster is reviewed for candidate. (Following Monday)

4.3.3.2 Employees must have card in by 8am on Wednesday of the bid week the opening is available and

be eligible to move per the CBA.

4.3.3.3 If there are any extra production workers in other areas, they are realigned to the area of need.

(once identified- moved the following Monday)

4.3.3.4 If there are any PW out on layoff, the layoff employees are recalled to work. (following Monday)

4.3.3.5 If there aren’t any extra in area or on layoff production workers, temps are identified to move into

those areas. (1-2 weeks to identify on average and move the following Monday)

4.3.3.6 If there aren’t any temps to move or are out of our temp timeline, PW are selected externally. (2

week timeline)

4.4 Temporary Employee Candidate Selection Process

4.5 If all internal bids are unsuccessful and we decide not to move lowest seniority PW, then the hiring process begins

4.5.1 If the decision is made to move temps to permanent positions

4.5.1.1 Supervisors in the area of need are asked to identify their “top performers”. (1-2 week process)

4.5.1.2 Supervisors complete a Performance review of the temps they feel would be good hires.

4.5.1.3 Attendance is also reviewed by HR and added to the performance review.

4.5.1.4 If the position in need has testing requirements, the selected temp must pass the test before they

can be hired into the position.

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R. Dhone 02/18/2015 QMSP 302

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4.5.1.5 Temporary employees must have a performance rating of 2.6 or higher to be considered for

permanent hire. If none identified go to step 2 for other department referrals.

4.5.1.6 If the superintendent’s department does not have temps or temps recommended for hire. (1-2

week process)

4.5.1.7 Other areas of the plant are asked to give referrals of “top performing” temps.

4.5.1.8 Each referred temp must have a performance appraisal completed to be considered.

4.5.1.9 Attendance is also reviewed by HR and added to the performance review.

4.5.1.10 If the position in need has testing requirements, the selected temp must pass the test before they

can be hired into the position.

4.5.1.11 The superintendent is given the option to interview the candidates for their area, since they are

unfamiliar with the temp and their performance.

4.5.1.12 The previous superintendent of the newly hired temp is asked if backfill for the temp is needed

once the temp is moved into their new position.

4.5.1.13 If the backfill is needed start the externally hiring process in IV.

4.6 Externally Candidate Selection process (2 week process if not a skilled position.aka CNC operator or Maintenance)

4.6.1 Employees are asked to sign up anyone they fill would be a good candidate.

4.6.2 An opening is submitted to the unemployment office.

4.6.3 Production workers are selected in the following order:

4.6.3.1 Sons and daughters (automatically qualified)

4.6.3.2 Family (automatically qualified)

4.6.3.3 Friends/unemployment office applications (automatically qualified except UE apps- they are

screened through and placed is preference order)

4.6.4 All bid positions are selected from either “word of mouth” or the unemployment office based on resume

qualifications.

4.6.4.1 The potential candidates must pass any required testing for the position.

4.6.4.2 Superintendent can interview and select their choice of potential candidates who qualify.

4.7 External Hire Process (2 week process)

4.7.1 Verbal offers are made to the candidates

4.7.1.1 Currently the offers are completely verbal. We do not have a formal offer process for any temp

or external candidate.

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4.7.2 Candidates selected to hire are then called by the HR admin

4.7.2.1 Candidates are scheduled for a physical and drug screen.

4.7.2.2 Candidates are instructed to bring government issued ID for proof of identity.

4.7.3 Candidate comes in for scheduled physical and drug screen

4.7.3.1 Candidates are schedule in the clinic for a drug screen and a basic physical.

4.7.3.2 The new instant drug screen cups in the clinic will produce immediate results.

4.7.3.3 In special cases due to dilute specimen or irregular temperature, the specimen might be sent off to

a lab for an additional test. When the specimen is sent to the lab it has about a 3 day turnaround.

4.7.3.4 After the candidate has completed both the drug screen and physical with passing results, he/she

is given a letter stating time of orientation and documents to bring.

4.8 Orientation (4 hours)

4.8.1 New employees are given approximately a 4 hour orientation

4.8.1.1 I-9 and new hire paperwork are completed at the time of orientation.

4.8.1.2 General policy and safety awareness is presented by HR, Union, and/or Safety Manager.

4.8.1.3 New employees sign a confirmation of orientation completion and policy understanding.

4.8.1.4 New employees are then assigned to work areas and shift.

4.8.2 HR enters the new employees and their new positions in the HR system

4.9 Training

4.9.1 Training quantity is variable depending on the position

4.9.1.1 Production Workers typically take about one week

4.9.1.2 Brazers- 1 week class; 2 weeks train up to speed to be able to complete joints

4.9.1.3 Run Test/Electrical wiring- 3-4 weeks

4.9.1.4 Positions such as CNC, Set-up, or Die Setter take extensive training



5.1.1 It is the responsibility of all Department Superintendents and Supervisors to assist in staffing requests

ensuring compliance with this procedure.

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0 Initial Creation of Procedure 2/18/15

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Handling, Storage, Packaging,

Preservation, and Delivery D. Presley 01 Page 1 of 2


S. Hassler 9/08/14 QMSP 400

Applicable to:


1.0 Purpose:

1.1 This procedure establishes minimum requirements for a material handling, storage, packaging, and delivery system

for components and finished goods.

1.2 These procedures apply to all fabricated components, raw materials, and finished goods.

2.0 References:

2.1 None

3.0 Definitions:



4.1 Handling

4.1.1 All materials shall be handled while in storage, in transit, or at point of use in such a manner as to

prevent damage or deterioration to raw materials, components, sub-assemblies, assemblies, and finished

goods.

4.1.2 The identification of new handling equipment or the suitability of existing equipment is determined

when a new product is identified. These include material handling equipment, transportation

requirements, packaging, containers, and storage areas.

4.2 Storage

4.2.1 Receiving authorization for raw materials and purchased components is the responsibility of the

Receiving Clerks of the Manufacturing Control Department. Authorization to receive raw materials and

purchased components is included in the Purchasing System.

4.2.2 Secure storage areas in the form of stores, racks and finished goods warehouse are provided for the

storage of raw materials, fabricated components, and finished goods.

4.2.3 Disbursements from storage areas shall require the appropriate move documentation form(s) or by

electronic transaction(s) to ensure accurate inventory record keeping, correct identification of

component dispatch, and traceability.

4.2.4 It is the responsibility of each Manufacturing Department Supervisor and Material Control Supervisor

to ensure that all materials and goods are protected from damage or deterioration while under their

control. Periodic monitoring of materials shall be performed to assess damage or deterioration to said

materials.

4.3 Packaging/Preservation

4.3.1 Material shall be stored and transported in or on a pallet, skid, basket, carton, or other container so as to

minimize the possibility of damage to components and to minimize the possibility of mixing similar

components.

4.3.2 Material shall be properly identified while in storage, transit, or completed to permit full identification

of the material.

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Handling, Storage, Packaging,

Preservation, and Delivery D. Presley 01 Page 2 of 2


S. Hassler 9/08/14 QMSP 400

Applicable to:


4.3.3 Identification shall minimize the possibility of mixing similar parts, prevent premature progression to

subsequent operations, and prevent premature dispatch.

4.4 Delivery

4.4.1 All materials, components, sub-assemblies, assemblies and finished goods are to be transferred and

delivered in such a manner as to protect the quality of the item being moved.

4.4.2 Delivery of material is to be initiated by the appropriate move documents or instructions.

4.4.3 Final delivery of the finished product is the responsibility of the Shipping Department.

4.4.4 The Shipping Department will ensure the product is delivered to and placed on the carrier's vehicle in

such a manner as to protect the quality of the finished product.


5.1 Manufacturing Control, Shipping, and Production are responsible for the enforcement of this procedure.


6.1 None




01 4.4.3 Removed: This includes carrier selection and verification of the carrier's

suitability to transport product.

9/08/14

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Product Identification and Traceability V. Losole 01 Page 1 of 2 Approved by: Effective date: Document No.:



1.1 This procedure defines minimum requirements for a Product Identification and Traceability System. 1.2 These procedures apply to all purchased fabricated components, raw materials, and finished goods.

2.0 References:

2.1 None

3.0 Definitions:



4.1 Objectives: The overall objective of this procedure is to establish guidelines for product traceability and identification in accordance with applicable Engineering Standards, Specifications, and Drawings.

4.2 Components 4.2.1 Incoming components corresponding to the required traceability listing are uniquely identified on each

component by the Supplier. Additional information is recorded as per QMSP 116. 4.2.2 Receiving Department is responsible for establishing and maintaining acceptance criteria. 4.2.3 Components designed to Rheem specifications will be identified by a part number.

4.3 Finished Goods 4.3.1 All finished goods will be identified by a model number and serial number permanently marked on the unit

in accordance with applicable Engineering Standards specified for that product. 4.3.2 The serial number will include a date code which signifies week and year of scheduled production date as

well as producing location. 4.3.3 Serial number generation and control is the responsibility of Division Production Control and Sales

Department. 4.3.4 Production and shipments of finished goods shall be captured by either scanning electronically or manually

entering serial and model numbers into a database designed for that purpose.


5.1 Manufacturing Control, Shipping, Division Production Control, Information Technology, Quality Assurance, and Production are responsible for the enforcement of this procedure.

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Product Identification and Traceability V. Losole 01 Page 2 of 2 Approved by: Effective date: Document No.:


Rheem Air Conditioning Division – Ft. Smith 6.0 Quality Records:

6.1 These records and databases will be retained by Quality Assurance and Information Technology for a period of time as specified in the corporate retention standard.



0 Initial issue of ISO 9001:2008 4/06/09 01 4.2.1 Deleted: for all incoming materials 4/29/09 01 4.2.2 Deleted: All records used to identify lots, origins, and acceptance criteria are

maintained by and are the responsibility of the Receiving Department. Inserted: Receiving Department is responsible for establishing and maintaining acceptance criteria.

4/29/09

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Purchasing Supplier Control D. Presley 01 Page 1 of 2


J. White 09/02/14 QMSP 500

Applicable to:


1.0 Purpose:

1.1 The purpose of this procedure is to establish the Quality requirements to ensure all purchased products conform to

Rheem's specified requirements.

1.2 This procedure also provides evidence that suppliers are monitored for continuous conformance to Rheem specified

requirements.

1.3 This procedure applies to all purchased products supplied to Rheem Manufacturing Company Air Conditioning

Division.

2.0 References:

2.1 Quality Management System Procedure 108, First Article Inspection (FAI)

2.2 Quality Management System Procedure 111, Supplier Assessment

2.3 QA 5.1.2-2A - 5.1.2-2E Supplier Self-Assessment Form

2.4 Quality Management System Procedure102, Corrective and Preventive Action Report

2.5 Quality Management System Procedure 116, Receiving Inspection

3.0 Definitions:



4.1 The Division Purchasing Department will initiate new supplier survey in Reliance. Corporate quality will complete.

4.1.1 The Division Purchasing Department will only use Suppliers who are on the "Approved Supplier List" or

Reliance or is in the process of being added to the list for parts and purchase orders which are repetitive in

nature.

4.1.2 New Suppliers will only be added to the "Approved Supplier List" per QMSP 111.

4.1.3 Suppliers for MRO, one-time use, and emergency situations are not required to appear on the "Approved

Supplier List".

4.1.4 Suppliers for Transportation Services may be added or deleted at the request of The Division Purchasing

Department or Rheem Traffic Manager.

4.1.5 Suppliers for calibration of equipment may be added at the request of the Plant Quality Assurance Manager.

4.2 The Purchasing Department will issue purchase orders containing purchased part numbers. Purchased part numbers

will have specs.

4.3 The Purchasing and Material Departments will be required to be the main contact point for the resolution of any

Quality problem between the Supplier and Quality Assurance.

4.4 The Purchasing and Materials Departments will ensure that all corrective action conforms to QMSP 102.

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Purchasing Supplier Control D. Presley 01 Page 2 of 2


J. White 09/02/14 QMSP 500

Applicable to:



5.1 It is the Division Purchasing Department responsibility to ensure compliance to this procedure at all facilities within

the Division.

5.2 Quality Assurance shall audit as required to ensure compliance to all requirements of this procedure.


6.1 Approved Supplier List

6.2 Supplier Self-Assessment Form (QA 5.1.2-2A - 5.1.2-2E)

6.3 Corrective and Preventive Action Report

6.4 Monthly Supplier Ranking System

6.5 Purchase Order




01 4.1

Removed: develop and maintain an “Approved Supplier List”.

Inserted: initiate new supplier survey in Reliance. Corporate quality will complete.

09/02/14

4.1.1

Inserted: or Reliance

4.2

Removed: ensure that all Purchase Orders for products used in the manufacturing of

Rheem’s and item will include the following requirements as a minimum.

Inserted: issue Purchase Orders containing purchased part numbers. Purchased part

numbers will have specs.

Removed 4.2.1 thru 4.2.5.

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Purchasing – Buying Plan Change Request M. McMillen 0 1 of 2


A.Green 9/30/15 QMSP 501

Applicable to:


1.0 Purpose:

1.1 The purpose of this procedure is to describe the workflow steps required to modifying the primary component used in

the BOM (Bill of Material) and planning requirements to transition into affected areas and planning processes.

2.0 References:

2.1 Buyer Plan Change Request form

3.0 Definitions:

3.1 Buying Plan Change Request - BPCR


4.1 Commodity Manager identifies part number(s) to be changed in the Bill of Material from alternate to primary, with

the intentions of a supplier buying plan change.

4.2 Commodity Manager works with Division R&D/Engineering to determine all Bills of Material (applications) where

the change will be requested, and gets confirmation that new part is set up as an approved substitute via ECN release

or confirmation that substitute part is identified in the Oracle BOM.

4.3 Commodity Manager works with Supplier/Division QA/Plant QA or other applicable parties to ensure that all

required PPAP activity has been completed for affected parts, and that BPA information has been set up.

4.4 Commodity Manager creates Buying Plan Change Request (BPCR) worksheet (double-click link below sample),

listing effective date as “TBD after pilot run.”

4.5 Commodity Manager communicates BPCR worksheet with Plant Material Manager, Plant Material Planner, Plant

Operations Manager, Plant Supplier Quality Manager and others as applicable. Operations team members confirm

quantity desired by Manufacturing for pilot run, and direct Material Planner to place an order with the supplier of line

test/pilot run quantities of new parts.

4.6 Plant Material Planner or designee places order for pilot run of new parts.

4.7 Once parts are received, Plant Material Planner or designee notifies Plant Operations Manager and Plant Supplier

Quality Manager (and any others in the plant specifically requesting notification). Plant Operations Manager or

designee sets time to use pilot quantity parts in production.

4.8 Plant Supplier Quality Manager informs Plant Operations Manager, Commodity Manager, Plant Material Manager,

and Plant Material Planner of whether or not the pilot run was successful and if there are any issues experienced by

the line.

4.9 Commodity Manager informs suppliers of impending change.

4.10 If pilot run is successful, the Commodity Manager works with the Plant Material Planner, Plant Material Manager,

Supplier and others as applicable, to determine an appropriate change date based on use-up plan existing inventory of

old parts in both the plant and supplier inventory, new part availability and lead time, and timing needed for BPCR

processing.

4.11 Commodity Manager updates the BPCR with planned Bill of Material change dates (based on assumed BOM update

date), and distributes to the Plant Material Manager, Plant Supplier Quality Manager, Finance, and Plant Operations

Manager for signature on worksheet.

4.12 Once signatures are compiled, the Commodity Manager will forward the BPCR worksheet to the Plant Material

Planner and MDEACC/R&D (copying worksheet signatories) requesting processing of the BPCR.

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Purchasing – Buying Plan Change Request M. McMillen 0 2 of 2


A.Green 9/30/15 QMSP 501

Applicable to:


4.13 MDAECC/R&D completes the requested BOM work per the BPCR document, and responds to those copied on

BPCR request from Commodity Manager that the BOM work has been completed.

4.14 Plant Material Planner confirms that new parts are showing expected MRP/forecast in the Oracle ASCP system, and

communicates any concerns or issues to MDAECC and Commodity Manager.

4.15 Plant Material Planner places orders for new parts.

Buying Plan Change Request

Date:

Commodity

Manager

Plant

Impacted Old Prime New Prime

Assumed BoM

Change Date

Effectivity

Date Models to Change (or attach list) Notes

Signatures Date

Commodity Manager

Plant Material Manager

Plant Quality Manager

Plant Operations Manager

Finance


5.1 It is the responsibility of the applicable commodity manager or designee to initiate and ensure the overall process is

applied where needed. In responsibilities identified above, appropriate activities may be delegated based on specific

needs and requirements of the organization and/or facility organizational structure.


6.1 Buyer Plan Change Request form



0 Initial issue of procedure 9/30/15

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Product Audit Procedures D. Dorrough 02 Page 1 of 3


T. Shellenberger 04/03/13 QMSP 600

Applicable to:


1.0 Purpose:

1.1 The purpose of the Audit Program is to ensure that our customers receive a quality product which incorporates both

safety and reliability.

1.2 These procedures apply to all finished goods and accessories.

2.0 References:

2.1 Audit Form F26.DGN

2.2 Quality Management Systems Procedure 102, Corrective and Preventive Action Report

2.3 Corrective and Preventive Action Report CAR-001

3.0 Definitions:



4.1 Objectives:

4.1.1 To provide a random sampling program of production items ranging from subassemblies to packaged

product as received by the customer.

4.1.2 To provide a laboratory audit inspection and testing above and beyond the quality inspection performed on

the products we manufacture.

4.1.3 To detect and isolate Manufacturing and Engineering problems before they become field problems.

4.1.4 To provide Manufacturing and Engineering personnel with information which may indicate possible trouble

areas and data for necessary corrective action.

4.1.5 To insure that each product conforms to Corporate and agency specifications.

4.1.6 To insure that changes in our product line are implemented as scheduled.

4.1.7 To create the effect of reducing service calls and customer dissatisfaction with our products.

4.1.8 To assist in providing our customers with the best quality product possible.

4.2 Audits shall be conducted in the Engineering Laboratory by Engineering personnel with the full facilities of the

Laboratory and Design Departments at their disposal.

4.3 Audits shall be conducted on a rotating or random basis. A continued audit of a particular product line may be

conducted to determine that required and documented product improvement changes are implemented.

4.4 Products to be audited include:

4.4.1 Completely packaged units from the end of the production line that have been accepted for shipment.

4.4.2 Subassemblies from the production line.

4.4.3 Recently stocked product in finished goods.

4.4.4 Field returned products.

4.4.5 Purchased product from customer warehouses or similar places of storage.

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Applicable to:


4.5 If a completely packaged unit from the end of the production line or from finished goods is selected for audit the

Auditor is to confer with Shipping to ensure that the selected item is not required for shipment to a customer. The

selected item for audit will either be picked up by the Auditor or delivered by Production or Shipping. For any

reason if the audit is estimated to exceed 5 working days the Auditor is to notify Shipping.

4.6 Deviations from Engineering specifications shall be factually recorded as Critical, Major, Minor, or Unclassified

defects on the audit form.

4.7 A Product Audit Report, Form F26.DGN will be completed by the auditor to record all defects and will be dispersed

to the audit distribution list. For Critical or Major Defects, Quality Assurance will assign a “CAR” Number and will

initiate distribution of the Corrective and Preventive Action Report Form, CAR-001. All Critical Defects will require

immediate “CAR” response and all Majors will require a “CAR” to be assigned within 5 working days from the time

the audit results are distributed. A copy of the CAR issued will be forwarded to the Auditor to be attached to the

corresponding audit.

4.8 Quality Assurance will be responsible for issuing and tracking Corrective and Preventive Action Report (CAR-001).

4.9 Should a recurring defect be noted, the following procedure is to be followed:

4.9.1 The defect is to be brought to the attention of the Plant Manager by means of a Corrective Action Request in

accordance with QMSP 102. He is requested to respond in writing regarding the steps being taken to correct

the problem or advise if the problem is not currently correctable.

4.9.2 If step one is unsuccessful, the Corrective Action may be elevated to the Vice President of R&D

Engineering.

4.10 The Auditor will classify defects and produce a typed report on Audit Form F26.DGN.

4.11 The Audit will be distributed by the individual facilities as required.

4.12 If R&D Engineering is to respond to the defect, the Corrective Action is to be issued with the initial Audit Report. If

the Engineering response cannot be formulated without delay, the audit is to be issued less responses. No delay

should be made in issuing the Audit Report.

4.13 Upon receipt of the Audit Report, it is the responsibility of the Department Manager of the Department responsible

for the defect to formulate the Corrective Action, type the description of the action in the space provided on the Audit

Report and/or "CAR" Form and issue copies of same to those parties deemed appropriate by Manufacturing.

4.14 Engineering is to receive a copy of the Audit Response and "CAR" for their files.

4.15 All defects characterized "Comments" are to be typed on a separate form and circulated or distributed within R&D

Engineering. A copy of the comments and action notations are to be filed with the Audit Report. See Audit

Comments Form F27.DGN in the Forms File located in R&D Print Room.

4.16 The number of units to be audited may vary from facility to facility, depending upon differing agency requirements,

i.e., UL, CSA, etc. Periodic tests will be conducted per the appropriate ANSI Standard. R&D will conduct a

minimum average of four product audits per month. The Vice President of R&D will have the authority to modify

the number of yearly product audits. This will be documented in the R&D Product Audit File.

4.17 In addition to audits on existing products, an audit of the pilot production of a new product will be completed, and all

defects noted. Corrections on all produced equipment must be made before the first shipment of the product will be

allowed.

4.18 Marketing, Manufacturing, and/or Engineering shall establish a list of the products, by model number and quantity, to

be audited prior to initial shipment.

4.19 Once a particular model has been audited and approved by Engineering (Marketing and/or Manufacturing may be

included in this decision), similar models may be shipped. No model that appears on the original list that has not

been audited, or approved as similar by all parties, may be shipped until audited.

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Applicable to:



5.1 Research and Development Department is responsible for conducting the product audits.

5.2 Quality Assurance shall audit to ensure this procedure is being complied with.


6.1 R&D will be responsible for maintaining a record of the product audits and responses to the listed defects.

6.2 These records will be retained by R&D for a period of time as specified in the corporate retention schedule and/or

Safety Agency Record retention requirement. Adherence will be given to extreme requirement.





01 Deleted: 4.10 & renumbered paragraphs 11/30/10

02 4.16 Deleted: six Inserted: four 04/03/13

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Deviation Request Procedures D. Presley 2 Page 1 of 2


B. Gahr 4/7/14 QMSP 601

Applicable to:


1.0 Purpose:

1.1 The purpose of the Deviation Request Procedure is to authorize the use of a part, component, or process that does not

conform to Engineering Specifications.

1.2 These procedures apply to all finished goods and accessories.

2.0 References:

2.1 Computer Software: Reliance

3.0 Definitions:



4.1 The information entered on the Electronic Deviation Request Form must be accurate and complete in describing the

conditions or changes that have been, or will be made. Drawings and/or part representation will be attached for

clarification.

4.2 Expiration dates will not exceed 60 days beyond the initiation date. If the number of units or parts are unknown, the

word "OPEN" will be entered in this space.

4.3 If it is later determined that the 60 day expiration date does not provide sufficient time to correct the problem or

revise the specifications, a new Electronic Deviation Request will be initiated.

4.4 The Electronic Deviation will automatically be routed to the appropriate personnel for review upon the completion

and submittal of the Electronic Deviation Request. A representative from each department will review and designate

either Approve or Reject.

ELECTRONIC APPROVALS

4.5 R&D: All Electronic Deviation Request Forms will be presented first to R&D for their approval.

4.5.1 R&D Engineering - The Deviation may be approved by a Engineering Manager, Design Engineer, Design

Services Manager, or their designates.

4.5.2 Agency Liaison: Must have an electronic approval of appropriate agency liaison or designate when agency

issues are involved

4.5.3 If Electronic Deviation Request is rejected by R&D, notification is sent to initiator of deviation, R&D and

Quality designates.

4.5.4 If Electronic Deviation Request is approved by R&D, the deviation is electronically routed to the

appropriate departments for review and approval.

4.6 Marketing: Deviation Requests will have an electronic approval of the appropriate Marketing Product Manager for

Deviations. If the appropriate Product Manager is not available, the approval of one of the other Product Managers is

permissible.

4.7 Purchasing: Any buyer or the Department Manager may approve Deviations. Only Deviation Requests involving

purchased parts must have a Purchasing electronic approval.

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Deviation Request Procedures D. Presley 2 Page 2 of 2


B. Gahr 4/7/14 QMSP 601

Applicable to:


4.8 Quality Assurance: Must have an electronic approval of the Quality Assurance Manager or designate on all

Deviation Requests.

4.9 Upon approval by all required departments, the Deviation Request is implemented. An email distribution is sent

notifying approval and implementation of Deviation Request.

4.10 If a Deviation is rejected by any one of the required departments, the Deviation Request is set to "Rejected" state.

The reason for rejection should be stated on the Deviation. Notification that the Deviation Request has been rejected

is sent to all pertinent departments and personnel.

4.11 All Electronic Deviations, whether approved or rejected are electronically maintained and stored.


5.1 The person responsible for originating the Deviation should be the person within the Department that is responsible

for the part, component, or process that is out of specification.


6.1 Corporate Quality will be responsible for maintaining a record of the Electronic Deviation Request Forms.

6.2 These records will be retained by Corporate Quality for a period of time as specified in the corporate retention

standard.




1 Updated procedures per Electronic Deviation process 6/22/09

2 2.1 Replaced Windchill PDMLink with Reliance

4.2 Removed: The Tooling, Drawing Section, and the Expiration Date should by filled in.

4.6 Removed: However, only Deviation Requests that effect performance and cosmetic issues

require Marketing approval.

Removed 4.8

6.1 Replace R&D with Corporate Quality

6.2 Replace R&D with Corporate Quality

4/7/14

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Engineering Change Notice Procedures T. Goines 0 Page 1 of 2 Approved by: Effective date: Document No.:

A. Kessler 4/06/09 QMSP 602 Applicable to:


1.1 To establish a procedure for releasing Engineering Specifications and issuing revisions to existing Specifications. 1.2 These procedures apply to all Drawings, Specifications, Bill of Materials, and Instructions released by R&D

Engineering Department.

2.0 References:

2.1 F39A.WK1: Change Notice Write-Up Form 2.2 Quality Management System Procedure 108, First Article Inspection (FAI)

3.0 Definitions:



4.1 A change to Engineering Specifications may originate as a result of a Engineering Change Request, Letter, Work Order, or Deviation Request.

4.2 Changes to Engineering Specifications must be approved by the Engineering Manager, Design Engineer, or the Design Services Manager (or Designee).

4.3 All Drawings and Instruction issued on the Change Notice will be initialed by a Draftsman, Designer, and/or the Engineer prior to release.

4.4 Approval of changes to computerized Bills of Material will be signified by initialing the "approved by" space on the Change Notice write-up.

4.5 An Engineering Change Notice will be issued whenever any Engineering Specification is released, revised, or discontinued.

4.6 The Change Notice write-up will include the following information: 4.6.1 The drawing number for the specification being revised or issued. 4.6.2 Current revision being released. 4.6.3 A description of the change as well as any special instructions relating to the change. 4.6.4 Disposition of inventory. 4.6.5 Change Notice Number. 4.6.6 The Product lines affected by the change. 4.6.7 The name of the individual making the release. 4.6.8 The initials of the individuals checking the release. 4.6.9 The initials of the individuals approving the release.

4.7 The Change Notice write-up will be approved by the Design Services Manager or a Designer that is not involved in making the release, the appropriate Engineer and Engineering Manager, Agency Liaison, and Division Purchasing Representative, when required.

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Engineering Change Notice Procedures T. Goines 0 Page 2 of 2 Approved by: Effective date: Document No.:



4.8 R&D will release the Engineering Change Notice to the appropriate Departments in all facilities. 4.8.1 Remote Facilities: Engineering Change Notices which affect products produced in the remote facility will

be sent to the R&D Manager at that facility. The R&D Manager will be responsible for assuring that all appropriate documents pertaining to the design requirements of a product will be available at those facilities.

4.9 The Production Manager will insure that the Change Notice is distributed to the appropriate Production Departments. 4.10 Quality Assurance shall audit to insure that obsolete documents are removed from points of issue or use.


5.1 Research & Development Engineering is responsible for issuing design specifications or revisions to existing specifications.

5.2 Quality Assurance is responsible to insure compliance with this procedure. 5.3 The Production Manager is responsible to insure that appropriate documents are in use. 5.4 Management and Supervision will insure that appropriate documentation is available for use within their respective

areas. 5.5 The appropriate Product Manager is responsible to ensure R&D is notified when a product is discontinued.


6.1 R&D ECN Master File 6.2 Engineering Specifications Master File 6.3 These records will be retained by R&D for a period of time as specified in the corporate retention standard.




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In-Process and Final Test Procedure T. Goines 0 Page 1 of 2 Approved by: Effective date: Document No.:



1.1 To establish a procedure for releasing in-process and final test requirements as defined by R&D Engineering which insure that the product is in compliance with all applicable agency requirements.

1.2 This procedure applies to all finished goods and accessories.

2.0 References:

2.1 ADS Instruction Drawings 2.2 Quality Management Systems Procedure 602, Engineering Change Notice Procedures 2.3 Quality Assurance Work Instructions

3.0 Definitions:



4.1 R&D will issue ADS Drawings as required to those Departments responsible for performing tests to insure that the final acceptance of all products meet the minimum requirements as set forth by R&D Engineering.

4.2 Quality Assurance, at their discretion, may expand on the ADS Test requirements by issuing Test or Work Instructions that detail how the tests may be performed. 4.2.1 Quality Assurance will ensure that all Work Instructions are clearly defined to those responsible for

performing the required test. 4.3 New or revised ADS Test Instructions will be issued on an Engineering Change Notice, by R&D Engineering, as

defined by QMSP 602.


5.1 R&D will be responsible for developing and issuing test instructions. 5.2 Quality Assurance will ensure compliance with this procedure.


6.1 ADS Master Drawing File. 6.2 Quality Assurance Work Instruction Log 6.3 Records will be retained by R&D for a period of time as specified in the corporate retention standard.



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In-Process and Final Test Procedure T. Goines 0 Page 2 of 2 Approved by: Effective date: Document No.:




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Quality Management System Procedures Title: Review by: Revision No.: Page: Design Development, Product Maintenance, and

Product Development B. Hanesworth 0 Page 1 of 2




1.1 Rheem Air Conditioning Division plans and controls the design development, continuing product maintenance and Product Development of our products. The Research & Development Department maintains control over the output results of these processes as new design development occurs and as product maintenance is completed. The Marketing Department maintains controls over the input requirements for new product development.

2.0 References:

2.1 Quality Management System Manual Section 10, Design and Development 2.2 Quality Management System Procedure 602, Engineering Change Notice Procedures 2.3 Engineering Change Request 2.4 Product Development Process Manual

3.0 Definitions:



4.1 Designs and Development Planning Rheem Air Conditioning Division will conduct Design Development planning in accordance with the Product Development Process. A test matrix will be utilized at the onset of the design stage to ensure that appropriate testing is performed. Product Maintenance will be conducted in accordance with Engineering Change Request Procedures.

4.2 Design and Development Inputs The Project Team will provide a Product Design Requirements Agreement (PDRA) inputs prior to the onset of the Product/Process stage. The PDRA will include: new product requirements and the business justification for the project. This will be prepared by the Project Team and approved by the Gate Review Board.

4.3 Design and Development Outputs The Research and Development Department will provide a required listing of Design Development outputs during the product development stages. Research and Development will include a test matrix that will be used to track the testing status and performance of the final product. Other design outputs will include Bill of Materials, Specification sheets, and Instruction and Operation Manuals.

4.4 Design and Development Review The Gate Review Board conducts scheduled meetings in order to maintain status updates on new Product Development issues. Minutes of the meetings will be available for review and maintained by the respective Gate Review Board Chairman.

4.5 Design and Development Verification Verification of Design Development will be conducted according to the test matrix that is developed by the Product Engineer and approved by the Engineering Manager.

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Quality Management System Procedures Title: Review by: Revision No.: Page: Design Development, Product Maintenance, and

Product Development B. Hanesworth 0 Page 2 of 2




4.6 Design and Development Validation The Research & Development Laboratory will conduct validation of the Design Development. Validation criteria will be determined and documented in the Design Development planning stage. Records of this validation will be maintained by the Research & Development Department.

4.7 Control of Design and Development Changes Design Development and Product Maintenance changes are identified and records will be maintained by the Research & Development Department. Engineering Changes Notices will be used to distribute information on new products as well as product maintenance. This will be done in accordance with Quality Management System Procedure 602. Continuing design changes can be submitted using the Engineering Change Request Form.


5.1 Research and Development Department has the responsibility for effective planning, utilizing design inputs, developing design outputs and reviewing these processes. The Research and Development Department also has the responsibility for verification and validation of new designs as well as maintaining current product maintenance change Quality Records:


6.1 Records associated with the design development and product maintenance are maintained by the Research & Development Department. The records include: Test Matrix, Test Schedule, Lab Books, Audit Report, Bill of Material, R & D Database (A/C, Commercial products only), and ECN. Records associated with product development are maintained by the Marketing Department. Records include the signed PDRA, Project Schedule, Meeting Minutes, and Gate Review Checklists. Records associated with this procedure are maintained in accordance with the Corporate Retention Policy.




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Contract Review D. Presley 02 Page 1 of 2


L. Shelby 9/05/14 QMSP 700

Applicable to:


1.0 Purpose:

1.1 The purpose of the procedure is to establish a procedure that defines the contract revision process within Rheem.

1.2 This procedure applies to all products manufactured or produced by the Rheem Air Conditioning Division.

2.0 References:

2.1 None

3.0 Definitions:



4.1 The Customer Service Department receives orders by iStore, EDI, or FAX. Each order is reviewed by the order desk

personnel to assure the proper models, quantities, pricing, and the closest possible compliance to the requested ship

date.

4.2 Upon order receipt, EDI orders are released to the Scheduling Department, iStore orders are sent directly into our

system and faxed (manual) orders are keyed into the Order Entry System for scheduling production and/or shipment

of stock items.

4.3 An order acknowledgement is sent to the customer by FAX or email to confirm the details of the order. This

acknowledgement resolves all discrepancies.

4.4 Customer changes to an order are handled as stated in Sections 4.1 - 4.3. A reacknowledgement is sent to them by

the same methods.

4.5 Changes to orders that cannot be made on line by the order center personnel are sent by email and forwarded to the

Plant Scheduling Department. A copy is scanned and electronically stored with sales order.

4.6 Sales order changes are normally processed on the same day as received by the Plant Scheduling Department.

Production schedules are revised as required and the producing plant's Manufacturing Control office notified via

telephone of the change. The Manufacturing Control Office then retrieves the production documents. Changes to

orders released to shipping are changed electronically on line, which prevents the Shipping Department from creating

shipping documents until the next day. The sales order changes are reflected in the next day's released order listing.

Should shipping be loading the order to be changed, a warning message is displayed to Division Production Control,

which then contacts the Shipping Department to determine the loading status of the order, and the appropriate action

taken based upon that information. Sales order changes are filed within the department after processing.


5.1 The Division Customer Service Manager will ensure compliance to this procedure.

5.1.1 Quality Assurance shall audit as required to ensure compliance to this procedure.


6.1 All records are stored electronically in accordance with the Record Retention Policy.

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Contract Review D. Presley 02 Page 2 of 2


L. Shelby 9/05/14 QMSP 700

Applicable to:





01 4.5 Deleted: noted on a sales order change form; Inserted: sent by email 10/27/09

02 4.1 Replaced: “National Order Center” with “Customer Service Department”

Replaced: “mail, Rheemote.Net” with “iStore”

4.2 Replaced: “These orders are then keyed into the” with “Upon order receipt, EDI

orders are released to the Scheduling Department, iStore orders are sent directly into our

system and faxed (manual) orders are keyed into the”

4.3 Replaced: “mail” with “email”

4.4 Removed: “, if necessary”

9/05/14

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Customer Reporting Systems D. Stokes 0 Page 1 of 2


B. Hanesworth 4/06/09 QMSP 701

Applicable to:


1.0 Purpose:

1.1 This procedure establishes the requirements for maintaining a customer reporting system to record and resolve any

product defects that may reach our customers, and to initiate positive corrective action for preventing future product

non-conformances.

1.2 This procedure is applicable to the Product Service and Support Group and the Customer Service and Support Group.

2.0 References:

2.1 CRIS Data Reporting System, Field Service Inspection Reports.

2.2 See Attachments:

2.2.1 Consumer Flowchart

2.2.2 Customer Relations Systems/Rheemote.Net

2.2.3 Help Desk Technical Assistance Diagnosis & Correction of Product Problems

2.2.4 Glossary of Terms

3.0 Definitions:



The Product Service and Support Group and Customer Service and Support Group will:

4.1 Identify areas of concern and product problems so as to assure the expected product reliability of and best customer

satisfaction with the products that Rheem manufactures.

4.2 Respond to user inquiries and complaints so as to achieve best customer satisfaction. (See Consumer Flowchart)

4.3 Provide technical assistance for diagnosis and correction of product problems. (See Help Desk Technical Assistance

Flowchart)

4.4 Monitor and evaluate product performance through customer complaints, warranty part returns, field inspections and

other sources of information: and assure a suitable solution to resolve these complaints.

4.5 Supply information to R&D Engineering, Product Management, Manufacturing, and Quality Assurance to assist in

correcting deficiencies and improving products. (See Help Desk Technical Assistance Flowchart)

4.6 Provide training and instructions to upgrade the performance of the Customer Service and Support personnel and

Product Service and Support Group, distributors and contractors.

4.7 Take positive steps to identify and communicate product defects. (See Help Technical Assistance Flowchart)


5.1 The Product Service and Support Group and Customer Service and Support Group are responsible for maintaining

this procedure.

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Customer Reporting Systems D. Stokes 0 Page 2 of 2


B. Hanesworth 4/06/09 QMSP 701

Applicable to:



6.1 CRIS Reporting System

6.2 Field Service Inspection Reports



Description Effective Date


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Consumer Flowchart

Gather Information

Fax or MailLiterature

DetermineAction(s)

Req.

Contractor

Installation

EquipmentContact

Contractor toWork w/Dist

STOP

WarrantyException

Advise CanChoose

Another

ExplainParts/Service

Warranty

NotifyDist.

STOP

Call DSCAdvise

Situation

ProvideRequested Information

Problem

InformationRequest

LiteratureRequest

None Available

Possible

No

Yes

Incoming Call,

Letter, or E-mail

-Model Number-Serial Number-Name-Address-Telephone Number-Req. Statement-Contractor Name-Contractor Number

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LKCDEPRAG

082901

Rheemote.net

PTS

HistoricalLibrary

E-Warranty

Distributors

Rheem Staff

Contractors

All Security•I & O’s

•JSIS•Wiring Diagrams•Charge Info•Spec SheetsDistributor Security•TCC’s

•Trade Branded ItemsStaff Security•Sensitive Items•Beta Testing

Special Security

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Help Desk Technical Assistance

Diagnosis and Correction of Product Problem

Consult KnownResolutionResources

SufficientInformation

ToSupportClaim.

GatherAdditional Information

DefineProblem

Yes

Incoming Call

Gather Information

Provide DetailsTo AppropriateDept / Person forInformation andResponse

Sufficient?

-Model Number-Serial Number-Problem. Statement-Name -Phone Number-JSIS Type Info

YesNoSTOP

ProductProblem?

Common BodyOf Knowledge

Hard CopyResources

On LineResources

NoSolutionAvailable?

Escalate to QIC,QA, R&D, Mfg.,

Prostock, etc

ResponseGiven

ResolutionDeveloped

ResponseReceived?

Resolve

Yes

Yes

No

STOPNo

Yes

No

Identify product problems (areas of concern)

Via technical assistanceProduct Service Specialist

Product ManagerRef

4.1

4.4

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Glossary of Terms

ACD Automatic Call Distribution

AG Attorney General

ATP Available To Promise

BBB Better Business Bureau

CC Call Center

CRC Customer Relations Clerk

CRR Customer Relations Representative

CRIS Customer Response Information System

DSC Distributor Service Consultant

DSM District Sales Manager

DTR District Technical Representative

FG Finished Goods

HD Help Desk

I & O Installation and Operation Instructions

JSIS Job Site Information Sheet

RA Return Authorization

TCC Technical Communications Center (Distributor Bulletins)

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Glossary R. Werschky 01 1 of 9


B. Gahr 2/10/14 1000

Applicability:


ADS – Instruction Drawing issued by R&D Engineering.

APPROVAL – A critical dimension for a part, sub-assembly, or assembly which has obtained a Cpk level 1.33 or greater and no

discrepancies exist.

ASSEMBLY CONFIRMATION – Predetermined quantity of units that represent the proposed design change and will be

assembled by manufacturing to ensure form, fit, and function parameters prior to pilot run.

ASSEMBLY LINE – The various areas of the plant where raw material, press parts, and sub-assemblies are assembled into

finished goods. Also defined as a valid inventory location for certain components.

AUDIT – Systematic, independent and documented process for obtaining audit evidence and evaluating it objectively to

determine the extent to which audit criteria are fulfilled [ISO 9001:2008 - 3.9.1].

AUDIT CRITERIA – Set of policies, procedures or requirements used as a reference [ISO 9001:2008 - 3.9.3].

AUDIT CONCLUSION – Outcome of an audit provided by the audit team after consideration of the audit objectives and all audit

findings [ISO 9001:2008 - 3.9.6].

AUDIT EVIDENCE - Records, statements of fact or other information which are relevant to the audit criteria and verifiable [ISO

9001:2008 - 3.9.4]

AUDIT FINDING – Results of the evaluation of the collected audit evidence against audit criteria. (NOTE: Audit findings can

indicate either conformity or nonconformity with audit criteria, or opportunities for improvement. [ISO 9001:2008 - 3.9.5]).

AUDIT PROGRAM –Set of one or more audits planned for a specific time frame and directed towards a specific purpose. NOTE

1 One auditor in the audit team is generally appointed as audit team leader [ISO 9001:2008 - 3.9.2].

AUDIT TEAM – One or more auditors conducting an audit [ISO 9001:2008 - 3.9.10].

AUDITEE – Organization being audited [ISO 9001:2008 - 3.9.8].

AUDITOR – Person with the competence to conduct an audit [ISO 9001:2008 - 3.9.9].

CALIBRATION – Comparing measuring and test equipment with measurement standards of known accuracy, the purpose being

to detect and adjust deviations from the standards.

CALIBRATION CONTROL – A documented system for assuring that inspection, measurement, and test equipment devices and

measurement standards are calibrated, and that this is done at intervals that assure their accuracy.

CALIBRATION INTERVAL – The period of time between calibrations. Intervals can vary for devices depending upon their

stability, purpose, and degree of usage.

CALIBRATION RECALL – A system for indicating in advance for each inspection, measuring and test equipment device and for

each measurement standard the date when it is next due to be calibrated.

CAPABILITY - Ability of an organization, system, or process to realize a product that will fulfill the requirements for that

product [ISO 9001:2008 - 3.1.5]

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CERTIFICATION – Approval given for the use of newly acquired, reworked, or modified inspection, measuring and test

equipment devices or processes following an examination that has verified that they are compatible with other devices or

processes in the system and when calibrated according to specifications are accurate and capable of fulfilling intended functions.

CERTIFIED PRINT – A released Engineering Drawing.

CHARACTERISTIC – Distinguishing feature [ISO 9001:2008 - 3.5.1].

COMPETENCE – Demonstrated ability to apply knowledge and skills [ISO 9001:2008 – 3.9.12].

CONCERNS – Opportunities for continuous improvement identified by Audits.

CONCESSION – Permission to use or release a product that does not conform to specified requirements [ISO 9001:2008 -

3.6.11].

CONFORMITY – Fulfillment of a requirement [ISO 9001:2008 - 3.6.1].

CONTINUAL IMPROVEMENT – A recurring activity to increase the ability to fulfil requirements [ISO 9001:2008 - 3.2.13]

CONTROL CHARACTERISITC – Part features which are essential to form, fit, function, safety, reliability, or sub-sequent

processing. These features will be noted as a boated dimension. These dimensions are subject to statistical capability and control

requirements.

CONTROL PLAN – A written description of the system for controlling the ongoing quality of parts. The plan should itemize the

following for each characteristic: the evaluation method, sample size and frequency, analysis method, and corrective action plan.

CORRECTION – Action taken to eliminate a detected nonconformity [ISO 9001:2008 - 3.6.6].

CORRECTIVE ACTION - Action to eliminate the cause of a detected nonconformity or other undesirable situation (NOTE

There is a distinction between correction and corrective action)[ISO 9001:2008 - 3.6.5].

CRITICAL DEFECT – A critical defect is an unsafe product discrepancy which could cause injury to a person during normal

designed use of the product or injury to a competent repairman performing routine maintenance. Such a product discrepancy may

be of the type considered to be reported to the Federal Consumer Product Safety Commission.

CUSTOMER – Organization or person that receives a product (or service) [ISO 9001:2008 - 3.3.5].

CUSTOMER RECORD INFORMATION SYSTEM (CRIS) – Computer software used to track customer issues.

CUSTOMER SATISFACTION – Customer’s perception of the degree to which the customer’s requirements have been fulfilled

[ISO 9001:2008 - 3.1.4].

DEFECT - Non-fulfillment of a requirement related to an intended or specified use (NOTE The distinction between defect and

nonconformity is important as it has legal connotations, particularly those associated with product liability issues; consequently,

the term “defect” should be used with extreme caution)[ISO 9001:2008 - 3.6.3].

DESIGN AND DEVELOPMENT – Set of processes that transforms requirements into specified characteristics or into the

specification of a product, process or system [ISO 9001:2008 - 3.4.4].

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DEVIATION – Permission in writing from the R&D Engineering Department to deviate from specified requirements for a given

number of units or for a specific period of time.

DEVIATION PERMIT- Permission to depart from the originally specified requirements of a product prior to realization [ISO

9001:2008 - 3.6.12].

DISTRICT TECHNICAL REPRESENTATIVE (DTR) – Product Management and Support personnel who are liaison between

the A/C Division and their customers.

DOCUMENT – Information and its supporting medium [ISO 9001:2008 - 3.7.2].

DROP-OFF – Nonconforming material which cannot be used for it’s intended purpose which can be diverted into some other use.

ENGINEERING CHANGE NOTICE (ECN) – Document utilized by the R&D Department to release drawings, specifications,

bill of materials, and instructions.

END ITEM – Any product that is supplied to the consumer for use.

ENGINEERING SPECIFICATION – All Bill of Materials, Drawings, Specifications, and Instructions issued by R&D.

EFFECTIVENESS - Extent to which planned activities are realized and planned results are achieved [ISO 9001:2008 - 3.2.14]

FIELD TEST – Validation of product design in field application.

FINDINGS – Direct violations of ISO requirements which is detected in an audit. This will be addressed by a Corrective Action

Report.

FIRST ARTICLE INSPECTION (FAI) – The status of a purchased part to ensure conformances to Engineering Specifications.

FIRST PART APPROVAL (FPA) – The status of an assigned part, sub-assembly, or final assembly to ensure conformance to

Engineering Specification.

FOLLOW-UP AUDIT - A special audit performed to verify that corrective action has been implemented as scheduled and that the

action was effective in preventing or minimizing recurrence.

GENERATED SCRAP – Material that is discarded during the normal performance of a production operation on a blank sheet of

steel, copper, or aluminum, such as edge trimming and hole piercing. To be considered as generated scrap, the discards must be a

part of the standard material allowance for making the part.

INCOMING INSPECTION – The inspection of purchased parts to ensure compliance with specifications and contractural

agreements.

INDEPENDENCE - Freedom from bias and external influence; provides for objectivity and impartiality.

INFORMATION - Meaningful data [ISO 9001:2008 - 3.7.1]

INFRASTRUCTURE - System of facilities, equipment and services needed for the operation of an organization [ISO 9001:2008 -

3.3.3]

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INSPECTION – Conformity evaluation by observation and judgement accompanied, as appropriate, by measurement, testing or

gauging [ISO 9001:2008 - 3.8.2].

INSPECTION, MEASURING, AND TEST EQUIPMENT – All devices used to measure, gauge, test, inspect, or otherwise

examine items to determine compliance with specifications.

INSPECTION RECORD - Document stating results (data) concerning inspection activities.

LEAD AUDITOR - The individual who manages the audit team during an audit.

MAINTENANCE WORTHY ITEM – A piece of equipment or tooling that has been determined to be of significant value or

importance to warrant inclusion into the Preventive Maintenance Program.

MAJOR DEFECT - A major defect is a defect that will result in a product failure or drastically reduce reliability of the product

for its intended purpose under normal use. Major defects will fit one or more of the following definitions:

a) Detracts from appearance to the point where a reasonable customer will return the product.

b) Affects the reliability or function to the point that a service call for adjustment or parts replacement is needed in order to

get satisfactory performance of a newly installed product.

c) Discrepancies in carton marking, rating plates, etc. which would prevent proper identification of product model or

product traceability.

d) Missing parts, extra parts or the unauthorized substitution of parts that would adversely affect performance.

e) The absence of or incorrect literature or wiring diagrams which would result in a faulty installation.

MANAGEMENT SYSTEM – A system to establish policy and objectives and to achieve those objectives [ISO 9001:2008 -

3.2.2].

MEASUREMENT CONTROL SYSTEM – Set of interrelated or interacting elements necessary to achieve metrological

confirmation and continual control of measurement processes [ISO 9001:2008 - 3.10.1].

MEASUREMENT PROCESS – Set of operations to determine the value of a quantity [ISO 9001:2008 - 3.10.2].

MEASUREMENT STANDARD (INTERIM) – A device used as a standard until an authorized standard is established.

MEASUREMENT STANDARD (REFERENCE) – An instrument or device of the highest order of accuracy which is used in a

calibration system as a primary standard of reference, its accuracy traceable to the National Institute of Standards and

Technology.

MEASUREMENT STANDARD (TRANSFER) – An instrument or device in a calibration system used to transfer measurements

from the reference standard to a lower echelon “working” standard or directly to the inspection, measuring or test equipment

being calibrated so as to avoid wear or deterioration of the reference standard.

METROLOGICAL CONFIRMATION – Set of operations required to ensure that measuring equipment conforms to the

requirements for its intended use. (NOTE Generally includes calibration or verification, any necessary adjustment or repair, and

subsequent recalibration, comparison with the metrological requirements for the intended use of the equipment, as well as any

required sealing and labeling) [ISO 9001:2008 - 3.10.3].

MEASURING EQUIPMENT – Measuring instrument, software, measurement standard, reference material or auxiliary apparatus

or combination thereof necessary to realize a measurement process [ISO 9001:2008 - 3.10.4].

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METROLOGICAL CHARACTERISTIC – Distinguishing feature which can influence the results of measurement [ISO

9001:2008 - 3.10.5].

METROLOGICAL FUNCTION - Function with organizational responsibility for defining and implementing the measurement

control system [ISO 9001:2008 - 3.10.6].

MINOR DEFECT – A minor defect is considered to be deviation from established standard of appearance or product performance

(other than major defects) which could have an adverse effect on product integrity or saleability but not sufficiently serious to

prompt a customer return or service call of an individual product. Minor defects would likely be noticed by an alert customer.

Minor defects must not be permitted to continue and would not be acceptable if present on a majority of the products. All safety

related defects are excluded from this category.

NONCONFORMING MATERIAL – Materials, parts, or components that fail to conform to specified requirements for any

Quality characteristic.

NONCONFORMITY – Non-fulfillment of a requirement [ISO 9001:2008 - 3.6.2].

OBJECTIVE EVIDENCE – Data supporting the existence or verity of something [ISO 9001:2008 - 3.8.1]

OBSERVATION – A concern or weakness detected in an element in the management system, but is not a nonconformance; a

condition that may become a nonconformance if not addressed; an opportunity for improvement.

OBSOLESCENCE – Surplus production material on which all efforts to find a use have been exhausted. Charged against Raw

Material reserves, accrued against “Raw Material” on P&L Statement.

OPENING MEETING - The introductory meeting between the auditor(s) and the auditee’s representative, at which time the

overview of the planned audit is presented.

ORGANIZATION – Group of people and facilities with an arrangement of responsibilities, authorities and relationships [ISO

9001:2008 - 3.3.1].

ORGANIZATIONAL STRUCTURE – Arrangement of responsibilities, authorities and relationships between people [ISO

9001:2008 - 3.3.2].

PARTS PER MILLION (PPM) – Metric used by Rheem to describe various defect levels.

PILOT RUN – Confirmation of Engineering Specifications and manufacturing processes prior to scheduled production.

PRE-AWARD SURVEY - An activity conducted prior to a contract award and used to evaluate the overall quality capability of a

prospective supplier or contractor.

PREVENTIVE ACTION – Action to eliminate the cause of a potential nonconformity or other undesirable potential situation

(NOTE Preventive action is taken to prevent occurrence, whereas corrective action is taken to prevent recurrence)[ISO

9001:2008 - 3.6.4].

PREVENTIVE MAINTENANCE – Those tasks that must be completed by “skilled” personnel such as Maintenance Personnel or

Toolmakers.

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PROCEDURE - Specified way to carry out an activity or process [ISO 9001:2008 - 3.4.5].

PROCESS – Set of interrelated or interacting activities which transforms inputs into outputs (NOTE 1 Inputs to a process are

generally outputs from other processes; NOTE 2 Processes in an organization are generally planned and carried out under

controlled conditions to add value; NOTE 3 A process where the conformity of the resulting product cannot be readily or

economically verified is frequently referred to as a “special process”)[ISO 9001:2008 - 3.4.1].

PROCESS CAPABILITY STUDY – A preliminary assessment of the potential capability of a process or tool to produce parts

that meet the requirements.

PROCESS CENTERING CAPABILITY INDEX (Cpk) – A measure of process performance that measures the centering and

variability of a process in relation to specific limits.

PROCESS CHANGE – Any significant change in the processing that might affect the conformance of the part produced.

PROCESS POTENTIAL STUDIES – A preliminary statistical evaluation of estimated process capability to consistently produce

parts that conform to Engineering Specifications.

PRODUCT – Result of a process. (NOTE 1 There are four generic categories of product: 1) Services, 2) Software, 3) Hardware,

4) Processed materials; [ISO 9001:2008 - 3.4.2].

NOTE: For the purposes of its ISO 9001 Certification, {Rheem Air Conditioning}’s product consists of the

heating, ventilation, and air conditioning equipment.

PRODUCTION PART APPROVAL PROCESS (PPAP): a process guideline that details the specific reports and documentation

necessary to gain part approval.

PRODUCTION USAGE – Any part used for normal pilot or production assembly.

PROJECT – Unique process, consisting of a set of coordinated and controlled activities with start and finish dates, undertaken to

achieve an objective conforming to specific requirements, including the constraints of time, cost and resources [ISO 9001:2008 -

3.4.3].

QUALITY – Degree to which a set of inherent characteristics fulfils requirements [ISO 9001:2008 - 3.1.1].

QUALITY ASSURANCE – Part of quality management focused on providing confidence that quality requirements will be

fulfilled [ISO 9001:2008 - 3.2.11].

QUALITY CONTROL – Part of quality management focused on fulfilling quality requirements [ISO 9001:2008 - 3.2.10].

QUALITY IMPROVEMENT – Part of quality management focused on increasing the ability to fulfil quality requirements [ISO

9001:2008 - 3.2.12]

QUALITY IMPROVEMENT COMMITTEE (QIC) – A management team focused on increasing the ability to fulfill quality

requirements.

QUALITY MANAGEMENT SYSTEM (QMS) – A management system to direct and control an organization with regard to

quality [ISO 9001:2008 - 3.2.3].

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QUALITY MANAGEMENT SYSTEM MANUAL (QMSM) – The top level of documentation for the Quality Management

System used by Rheem Air Conditioning Division.

QUALITY MANAGEMENT SYSTEM PROCEDURES (QMSP) – The second level of documentation for the Quality

Management System used by Rheem Air Conditioning Division.

QUALITY MANUAL - Document specifying the quality management system of an organization [ISO 9001:2008 - 3.7.4].

QUALITY OBJECTIVE - Something sought, or aimed for, related to quality (NOTE 1 Quality objectives are generally based on

the organization’s quality policy; NOTE 2 Quality objectives are generally specified for relevant functions and levels in the

organization)[ISO 9001:2008 - 3.1.1]

QUALITY PLAN - Document specifying which procedures and associated resources shall be applied by whom and when to a

specific project, product, process or contract [ISO 9001:2008 - 3.7.5].

QUALITY PLANNING – Part of quality management focused on setting quality objectives and specifying necessary operational

processes and related resources to fulfil the quality objectives [ISO 9001:2008 - 3.2.9].

QUALITY POLICY - The overall intentions and direction of an organization related to quality as formally expressed by top

management [ISO 9001:2008 - 3.2.4]

RACKS – A valid inventory location defining the various areas of the plant where fabricated press parts are located.

RECORD - Document stating results achieved or providing evidence of activities performed [ISO 9001:2008 - 3.7.6].

RELEASE - Permission to proceed to the next stage of a process [ISO 9001:2008 - 3.6.13].

REMOTE FACILITY – Any facility outside of the Division location being Fort Smith.

REQUIREMENT - Need or expectation that is stated, generally implied or obligatory [ISO 9001:2008 - 3.1.2].

RESOURCES - People, time, money, buildings, equipment and support activities, as necessary, that may be applied to a specific

project, product, process and/or contract in order to fulfil requirements.

REVIEW – Activity undertaken to determine the suitability, adequacy and effectiveness of the subject matter to achieve

established objectives [ISO 9001:2008 - 3.8.7].

REVISION – Any authorized change to an existing drawing, specification, inspection instruction, test instruction, and any

approved released Quality Management System Procedures.

REWORKABLE MATERIAL – Nonconforming material that can be economically reworked to an acceptable condition.

ROOT CAUSE - The fundamental deficiency that results in a nonconformance that must be eliminated through corrective action

to prevent recurrence of the same or similar nonconformance.

ROOT CAUSE ANALYSIS - Investigation to determine the fundamental deficiency that resulted in a nonconformity.

SCRAP – Production material that is damaged beyond repair and cannot be diverted into another production part or recovered

from Supplier. Charge to “Spoilage” on P&L Statement.

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SERVICE – The result of at least one activity necessarily performed at the interface between the supplier and the customer and is

generally intangible. Provision of a service can involve: 1) Activity performed on a customer-supplied tangible product, 2)

Activity performed on a customer-supplied intangible product, 3) Delivery of an intangible product, 4) Creation of ambience for

the customer [ISO 9001:2008 - 3.4.2 NOTE 2].

SPECIFICATION – Document stating requirements [ISO 9001:2008 - 3.7.3].

STATISTICALLY VALID SAMPLE – A sample of product, from a stable process, of such size as to insure confidence that it

accurately reflects inherent variations of the population it was removed from.

STORES – A valid inventory location defining the various areas of the plant where raw material components are located.

SUPPLIER – Organization or person that provides a product [ISO 9001:2008 - 3.3.6].

SUPPLIER CERTIFICATION – A program designed to qualify Suppliers already on an approved status to a higher level of

approval called Certification. This usually encompasses review of the Supplier’s past delivered product history, and Supplier

Self-Assessment Survey.

SUPPLIER SELF-ASSESSMENT SURVEY – A survey conducted to assess whether the Supplier has appropriately controlled

systems which will adequately prevent the manufacture of nonconforming products. A Supplier Self-Assessment is not required

if the candidate Supplier provides a purchase part or parts that do not effect the fit, form, or function of a Rheem finished product.

Appendix C (Supplier Self-Assessment Cover Sheet) is still required to be completed by the candidate Supplier. The candidate

Supplier will be added to the Rheem Approved Supplier List after completion of Appendix C and once the required signatures

and information have been obtained.

SYSTEM - Set of interrelated or interacting elements [ISO 9001:2008 - 3.2.1]

TEST – Determination of one or more characteristics according to a procedure [ISO 9001:2008 - 3.8.3].

TOP MANAGEMENT – Person or group of people who directs and controls an organization at the highest level [ISO 9001:2008

- 3.2.7].

TOTAL MAINTENANCE SYSTEM – Computer software used to track Maintenance issues.

TOTAL PRODUCTIVE MANUFACTURING – A formal program utilized by Production, Maintenance, and Tool and Die

Departments to ensure all tooling and equipment meet or exceed design specification for quality, changeover time, and production

capacity.

TRACEABILITY - Ability to trace the history, application, or location of that which is under consideration [ISO 9001:2008 -

3.5.4].

TRADE BRAND – Products that are marketed under brand names other than Rheem, Ruud, or Weatherking.

UNCLASSIFIED DEFECT – Insignificant defects designated as “Unclassified” are usually caused by workmanship or design.

These types of defects are detected by plant inspection or Engineering personnel but would not normally be noticed by the

customer. The defect would not affect product integrity, saleability, or normal function of the unit.

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USE-AS-IS – Material that is found to be nonconforming in a minor way but suitable for its intended purpose and acceptable to

the Engineering requirements.

VALIDATION – Confirmation, through the provision of objective evidence, that the requirements for a specific intended use or

application have been fulfilled [ISO 9001:2008 - 3.8.5].

VERIFICATION – Confirmation, through the provision of objective evidence, that specified requirements have been fulfilled

[ISO 9001:2008 - 3.8.4].

WORK ENVIRONMENT - Set of conditions under which work is performed (NOTE Conditions include physical, social,

psychological and environmental factors (temperature, recognition schemes, ergonomics and atmospheric composition))[ISO

9001:2008 - 3.3.4]

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