Quality Manual

Mission Statement

Circuit Board Express' philosophy is continuous improvement of customer satisfaction. Its objective is to meet or exceed customer requirements.
Our mission is to continue to foster superior innovations in aligning our customer needs with our empowered employees and management partnership.

Below is an uncontrolled copy of our Quality Manual for your review.

Circuit Board Express's Quality Manual
Procedure QM-1, Rev. 13

TABLE OF CONTENTS
 

0.10 Scope

This quality manual describes the quality control system of Circuit Board Express Inc., as required by the ISO 9002 standard. It exclusively covers all printed circuit boards manufactured at the Haverhill, Massachusetts’s location.

0.20 Distribution and Manual Control

Controlled copies of this manual are provided to the manager of each department (see Table 1). These are stamped "CONTROLLED COPY" in red ink and have a copy number assigned to each. Copies of this manual stamped "UNCONTROLLED COPY" in red or photocopied, may be sent to our customers upon request, but are not included on the Distribution List and do not require Revision Control. There is also an uncontrolled copy of the manual available on our web site, www.circuitboardexpress.com

Table 1. Distribution List
 

0.30 Quality Policy

Circuit Board Express' philosophy is continuous improvement of customer satisfaction. Its’ objective is to meet or exceed customer requirements. Our mission is to continue to foster superior innovations in aligning our customer needs with our empowered employees and management partnership. It is required that all employees participate within the Quality Policy. This policy is posted in several areas and every employee has read and signed a copy, which is in their training file.

0.40 Organizational Chart

SECTION 1, MANAGEMENT RESPONSIBILITY

Company Policy- The President is ultimately responsible for establishing, implementing and maintaining the quality system. Specific responsibilities comprise: formulating the quality policy, defining the organization, assigning authorities and responsibilities, appointing the management representative, periodically reviewing the quality system, and making available the resources and personnel necessary to maintain the system.
Management Representative:
The President appoints the Operations Manager as the Management Representative. He or she has the authority and responsibility to ensure that the quality system is maintained and its efficiency is continuously improved, and that the system always complies with the requirements of the ISO 9002 standard.
Organization:
Inter-relations of personnel, who manage, perform and verify work-affecting quality, are defined on the organization chart on the previous page. The C.B.E. quality organization comprises of 4 functions:

• Operations
• Quality Control
• Customer Service
• Management Representative

Each function head reports directly to the President. The President and the function heads constitute the executive Management.
Responsibilities:

• President-Formulates the quality policy, initiates and supervises the quality system, provides resources necessary to maintain the system.
• Operations-Defines workmanship standards, follows up on Corrective and Preventive Actions, monitors quantities, controls and monitors processes, maintains production equipment, performs production engineering, administrates storage areas, administrates Product ID and traceability, determines production personnel and equipment requirements, verifies quality and quantity of received goods, maintains & calibrates measuring and test equipment, cares for building and grounds, orders approved purchasing requisitions, verifies quality and quantity of received goods, monitors and assesses supplier performance, tracks performance measurements, responds to customer comments.
• Quality Control-Initiates requests for Corrective Actions, assists with Internal audits, performs inspection & testing in accordance with the quality plan, handles non-conforming products, maintains inspection records
• Customer Service-Reviews Customer Specifications and delineates information as required, advertises and promotes company's products emphasizing their quality, aspects, timely deliveries and value, Provides quotation in a timely manner, provides customer liaison, service, responds to customer comments.
• Management Representative-Establishes and maintains the quality management system, conducts management reviews of the quality system, Record management review minutes, Prepares agenda,
  Assists with supplier quality surveys and audits, Leads Audit Team.

Management Review: The company's executive management reviews the quality system quarterly. Reports are available monthly and merged quarterly to show any trends developing or any repeating problems, which need to be addressed. The purpose of the review is to assess the effectiveness and continuing suitability of the quality system.
Management Representative is responsible for scheduling and conducting the reviews.
Records of management reviews are retained in accordance with procedure 4.16, Quality Records.

SECTION 2, QUALITY SYSTEM

Company Policy- Circuit Board Express has a documented and implemented quality management system that satisfies the requirements of ISO 9002. The quality system is documented in the quality manual, procedures, process flow charts, company technical standards, national and international standards, and the production and quality plans. Effectiveness of the quality system is regularly audited and reviewed.

Quality System Scope-Scope of the quality system is defined in the following documents:

• Quality Manual
• Procedures
• Work Instruction/Process Flow Charts
• Customer technical specifications and drawings
• Production and quality plans
• IPC 600 current revision
• ISO9002 current revision

The documents collectively define a quality system of ISO 9002 current revision.
Quality System Implementation- All personnel are responsible for implementing the quality system. The Lead Auditor is responsible for coordinating, monitoring and assisting in auditing the system. Implementation of the quality system is assessed regularly by way of internal audits and management reviews. (Reference procedures 4.17 Internal Quality Audits and 4.1 Management Review.)
 

Quality Plan
The purpose of production and quality plans are to sequence and coordinate production operations, define equipment to be used, and reference any specifications needed for production. Quality plans define the inspection and testing points, and also reference specific inspection instructions and acceptance criteria. The quality plans are documented on the batch card and the tooling package flow sheet. The batch card and the tooling package flow sheet lists all production and inspection steps required for the product.
Business scope description- Circuit Board Express is a manufacturer of printed circuit boards for the electronics, telecommunications, computer and similar industries providing routine deliveries of single sided through multilayer prototype lots in 24 to 72 hours.

SECTION 3, CONTRACT REVIEW

Company Policy- All quotes and orders are reviewed to assess if the customer's requirements are adequately defined, are well understood, and if the company has the capability to meet the contract or quote requirements. Procedure 4.3 documents Circuit Board Express's Contract Review System.
Application- There is a documented system for contract reviews. It is applicable to the customer's specification. The customer service department is responsible for conducting contract reviews for all products.
Scope of Review- The contract review comprises of verification that the customer's requirements are adequately defined, documented, well understood and that the company has the capability to meet the contract requirements.

Records- The customer service department conducts contract reviews and makes a record of each review. The order release is the contract review record. This order release includes the customer requirements needed by the Engineering and Production Departments. Records of contract reviews are retained in accordance with procedure 4.16, Quality Records.

SECTION 4, DESIGN CONTROL

Company Policy- Due to the fact that Circuit Board Express does not design* any of our products, this section does not apply. All products are designed by the customer and assumed to be checked prior to us receiving the order.
* The term design that we do perform is not the same definition, we use the term design for taking a customer’s data and routing the circuitry onto the printed circuit board. This "design" process is also verified by the customer. We do not design a product.

SECTION 5, DOCUMENT CONTROL

Company Policy- All documents are reviewed and approved prior to issue. Documents are available at locations where they are used. Obsolete documents are removed from points of use. The Management Representative is responsible for coordination and enforcing the document control related activities in accordance with procedure 4.5, Document Control.

Controlled Documentation- Quality system documentation comprises the following types of documents:

• Quality Manual- Level 1
• Procedures- Level 2
• Work Instructions and Process Flow Charts- Level 3
• Forms and Checklist- Level 4

Document Approval Issue- Any employee, department or approval committee can initiate a new document or document changes. All documents are reviewed and approved by the appropriate persons prior to issue. Level 1 and 2 documents display an approval list. The Management Representative maintains a master file of all internally generated documents. The master list is comprised of the document, revision, release date, and the locations of the documents. Documents are distributed to personnel and locations where they are used.

Document Changes- Document changes are reviewed and authorized by the same authority that issued the original document. Revised documents are distributed and obsolete documents are removed from points of use.

Customer Related Documentation- Customer related documents are comprised of:

• Customer drawings and specifications
• Workmanship criteria
• Customer supplied electronic data
• Customer supplied artworks

Engineering is responsible for the control of customer related documentation in accordance with procedure 4.5, Document Control.
Records- Document records are retained in accordance with procedure 4.16, Quality Records.

SECTION 6, PURCHASING

Company Policy- The company assesses its’ suppliers and subcontractors and purchases only from those that can satisfy the company's quality requirements. Purchasing documents clearly and completely describes ordered products, including quality requirements. Purchasing documents are approved prior to release. Procedure 4.6 and 4.6.1 document Circuit Board Express's Purchasing system.
Assessment of Subcontractors- The company differentiates between suppliers and subcontractors. Suppliers are defined as vendors who will deliver their standard catalog products, while subcontractors are outside services that design and/or manufacture products from the customer's specifications. Assessment of suppliers and subcontractors is carried out by the Management Representative and Purchasing. Purchasing monitors quality performance of all suppliers and subcontractors. Those showing inadequate performance are asked to implement corrective actions and are discontinued if there is no improvement in accordance with Procedure 4.6.1, Approved Supplier List. The Purchasing function maintains an approved supplier/subcontractor list. Orders that affect quality may only be placed with suppliers or subcontractors on the list.
Purchasing Data- The person requesting supplies prepares purchase requisitions. The documents clearly and completely describe requested products. They include precise identification of the products, reference applicable standards and state quality requirements.
Verification of Purchased Product- Circuit Board Express’s customer, their designee or Circuit Board Express may impose the requirement of source inspection to verify compliance to specified requirements. This may occur at Circuit Board Express or at the subcontractor/ supplier’s facility.
Responsibility- The Purchasing and Operations functions are responsible for maintaining this system.
Records- Records of the purchasing system are retained in accordance with procedure 4.16, Quality Records.

SECTION 7, PURCHASER SUPPLIED PRODUCTS

Company Policy- Customer supplied products are handled in the same manner as other products purchased for incorporation into the supplies. When specified in a contract, special handling instructions from customers will take precedent over the company's standard procedures. Loss, damage or unsuitability of a customer's product is recorded and reported to the customer. Procedure 4.7 documents Circuit Board Express's Purchaser Supplied Products System.
Procedure- Customer supplied products are reviewed, and stored in the same manner as other purchased products unless otherwise specified by the customer. The customer is contacted in the event of loss, damage, deterioration or unsuitability of product in accordance with procedure 4.13, Control of Non-Conforming Product.
Responsibility- The Customer Service and Operations functions are responsible for maintaining this system.

SECTION 8, PRODUCT IDENTIFICATION AND TRACEABILITY

Company Policy- A job number uniquely identifies products, which correlates to a corresponding customer drawing, data, specification and technical documents. Procedure 4.8 documents Circuit Board Express's Product Identification and Traceability System.
Part and Product Identification- All manufactured parts are identified with company's internal job numbers assigned by Customer Service. The job numbers provide for a correlation between a part and its technical documentation. When requested by the customer a unique date code will be applied to the product allowing for traceability to each release with a corresponding batch card.
Records- The job number of a product is the key to correlation with its parts lists, technical documentation and quality records. Records of this system are maintained in accordance with procedure 4.16, Quality Records.

SECTION 9, PROCESS CONTROL

Company Policy- Production and individual operations are planned and documented. Personnel performing complex or critical operations are provided with work instructions and workmanship criteria. Processes are controlled and performed in accordance with written procedures. Production equipment and processes are maintained and checked for adequacy prior to use. Production areas are clean and provide a suitable work environment. Procedure 4.9 documents Circuit Board Express's Process Control System.
Procedure- The production plan is specified on a batch card by Methods Engineering. Methods Engineering lists all production and inspection operations necessary to manufacture, verify, and ship a product. Personal performing the operation is trained for the task. Work instructions and workmanship standards are available to the personal performing the task.
Equipment and processes are verified to be working adequately prior to use. Procedure 4.9.2 documents our Preventative Maintenance system. Procedure 4.9.3 documents our Chemical Maintenance system.
Responsibilities- Process Engineering is responsible for maintaining this system.
Records- Records of the Process Control system are retained in accordance with procedure 4.16, Quality Records.

SECTION 10, INSPECTION AND TESTING

Company Policy- Inspection and testing are conducted when purchased materials are received, at significant stages of production, and prior to shipping finished products. The objective of inspections and testing is to verify conformance with specified requirements. Materials and products are prevented from being used or shipped until the required inspections are completed. Records of inspections are established and maintained as evidence that products comply with stated requirements. Procedure 4.10 documents Circuit Board Express's Inspection and Test system.
Receiving Inspection- Purchased products are subjected receiving inspection in accordance with procedure 4.10.1. All products are inspected visually, and then critical products, those products that have been manufactured from company specifications, are subjected to a more detailed and technical QC inspection.
In-Process Inspections- In-Process inspections are specified on a batch card accompany the product throughout the manufacturing process. In-process inspections are performed in accordance with procedure 4.10.2.
Final Inspection- Only those products that pass final inspection are admitted to the shipping area. Final inspection is performed in accordance with procedure 4.10.3
Non-Conforming Product- Non-conforming products found during any inspections are segregated and handled in accordance with procedure 4.13, Non-Conforming Product.
Records- Records of inspections and test are retained in accordance with procedure 4.16, Quality Records.

SECTION 11, INSPECTION, MEASURING AND TEST EQUIPMENT

Company Policy- The required measurement accuracy is known, and appropriate equipment is selected to perform the measurements. All measuring and test equipment is calibrated with traceability to a national standard. Calibration certificates are maintained and the calibration status of measuring equipment is identified. The equipment is well maintained and its placement and uses are controlled. Procedure 4.11 documents Circuit Board Express's Inspection, Measuring and Test Equipment system.
Measurement Identification- The Customer identifies measurement and the required accuracy on drawings. Selection of suitable equipment to perform those measurements is the responsibility of the Quality Control Department.
Calibration and Maintenance of Equipment- All equipment used for inspection, measuring and testing of products is calibrated with traceability to national standards. Calibration stickers identify calibration status of equipment. The Process Engineer maintains a list of measuring and test equipment, providing identification, placement and calibration status for each piece of equipment. Measuring and test equipment is maintained to preserve its accuracy and fitness for use.
Records- Records of are retained in accordance with procedure 4.16, Quality Records.

SECTION 12, INSPECTION AND TEST STATUS

Company Policy- Inspection and test status of a product is identified to assure that only product that has passed inspection is to be processed or shipped. Authority responsible for the release of confirming products is defined. Procedure 4.12 documents Circuit Board Express's Inspection and Test Status system.
General- Batch Cards and process flow charts prevent product from being used or dispatched before it passes the prescribed inspections.
Identification system- Products that pass the receiving inspections are moved to the correct department. Status of an in-process inspection is identified on a batch card accompanying the product. Products that pass the final inspection are identified by a Quality Control inspector signing and dating final inspection checklist, batch card and certificate of compliance.
Products that fail any one of the inspections are segregated until disposition in accordance with procedure 4.13 Control of Non-Conforming Product. Results of all final inspections are logged into the final log.
Authority to Release Product- The Quality Control inspector performing the final inspection has the authority to release the product for shipment. A product labeled inspected, signed and dated by the inspector on the final checklist is evidence that the product has been released for shipment.

SECTION 13, CONTROL OF NON CONFORMING PRODUCT

Company Policy- Non conforming product is identified, documented, evaluated, and prevented from being used or shipped. Responsibility for disposition of non conforming product is defined and, when required, the customer is contacted for advisement. Repaired or reworked product is re-inspected. Detailed rules for nonconformity review, making the disposition decision and recording these activities are provided in procedure 4.13, Control of Non-Conforming Product.
Identification and Documentation- All non-conforming product that can not be corrected using IPC Standards of repair or rework current revision is identified and documented. Discrepant material is segregated until a disposition is made. Documentation of nonconformity is made on the Discrepant Material Report.
Nonconformity Review and Disposition- Shift managers, Quality Control, Methods Engineer or the President are authorized to make the disposition decision for a non-conforming product. The disposition decision may be:
Use as is, Rework, Scrap, Return to Supplier. The customer is contacted for advisement or acceptance of a discrepant customer supplied product.
Re-Inspection- Repaired or reworked products are reinspected in accordance with the instructions on the Discrepant Material Report (DMR).
Records- Records of Discrepant Material Report are retained in accordance with procedure 4.16, Quality Records.

SECTION 14, CORRECTIVE & PREVENTIVE ACTION

Company Policy- The company recognizes that diligent and effective implementation of this corrective action policy is crucial to the success of the quality system. Procedures, work instructions, quality records, quality reports, internal audits and customer comments are analyzed to detect any sources of potential quality problems. Causes of non conformities are investigated and corrective actions are initiated to prevent recurrence. Controls are applied to ensure implementation and effectiveness. Procedure 4.14 documents Circuit Board Express's Corrective and Preventive Action System.
Initiation of Corrective Action-Anyone in the company may propose initiation of a corrective action, but only the quality department can assign a corrective action. Corrective actions are initiated as a result of:

• Identification of product nonconformity
• Customer complaints or recommendations
• Noncompliance observed during audits,
• Nonconformity's from a supplier/subcontractor

Action items stemming from any training meetings or Management Review Meetings will be assigned corrective actions as needed. Some examples are Process Quality Problems and Quality Reports.
Preventive Action- Preventive Action is done by analyzing information from process work instructions, audit results, quality records and customer comments. By the proper use of this information we can reduce or eliminate potential nonconformities.
Follow Up- Process or procedure related corrective actions require a follow up. The Management Review Team reviews Corrective Action system data for effectiveness in accordance with procedure 4.1, Management Review.
Records- Records of Corrective and Preventive Actions are retained in accordance with procedure 4.16, Quality Records.

SECTION 15, Handling, Storage, Packaging, Preservation and Delivery

Company Policy- Methods and means of handling that prevent product damage and/or deterioration are provided. Packaging is specified and controlled. Products are protected prior to and during delivery. Procedure 4.15 Documents the Handling, Storage, Packaging, Preservation and Delivery system at Circuit Board Express.
Handling- The Operations function is responsible for product handling and ensuring that equipment is clean, adequate and well maintained.
Storage- The storage areas and their operations are the responsibility of the Operations function. Only products that are properly identified are authorized to enter and leave the storage areas.
Packaging and Delivery- The customer preferred ship method is recorded on the order release form, if available. If the information is not available, the shipping department will choose a method to ensure on time delivery.
Customer Service specifies customer special packaging requirements on the order release form. If the customer does not specify packaging requirements the product will be packaged in a manner to prevent damage during delivery or storage.
Preservation- Any product at Circuit Board Express will be handled and packaged to preserve it. Shelf life items are rotated to ensure the earliest expiration date is used first.

SECTION 16, QUALITY RECORDS

Company Policy- Quality records demonstrate achievement of the required quality and effective operation of the quality system. The records are identified and stored in a suitable environment to minimize deterioration. Retention periods and storage locations for quality records are defined in procedure 4.16, Quality Records.
Procedure- The activities of identification, collection, filing, storage, maintenance and disposition of quality records are governed by procedures. Procedures that call for establishing of a record explain how it should be done, who is responsible and what rules apply for its filing and storage.
Identification and Storage- Records are identified to the product, person or the activity involved. When relevant, they are signed and dated.
Records are stored in an environment that will prevent damage.
When requested Quality records are given to the customer with the job folder, if the job will no longer be built here. The methods engineer records this.

SECTION 17, INTERNAL QUALITY AUDITS

Company Policy- Comprehensive, planned and documented internal quality audits are conducted. Audits are scheduled on the basis of the status and importance of the activity. Identified non conforming conditions are reported to the internal customer for appropriate action. Procedure 4.17 documents Circuit Board Express's Internal Quality Audit system.
Planning and Scheduling- The Management Representative establishes an internal audit plan and schedule. Every activity and area is audited at least once a year, but more frequent audits may be scheduled for critical processes of systems.
Audit Team and Preparation for Audit- Only personnel independent of the audited activities are assigned to conduct an audit. The Management Representative leads the audit team.
By reviewing the procedures the auditor establishes an audit checklists.
Follow Up- When non-conforming conditions are identified, the lead auditor will request the quality department initiate a corrective action.
Implementation and effectiveness of the corrective action is verified in accordance with Procedure 4.14, Corrective and Preventive Action.
The Management Review team reviews Internal Quality Audit system data for effectiveness in accordance with procedure 4.1, Management Review.
Records- Records of Internal Quality Audits are retained in accordance with procedure 4.16, Quality Records.

SECTION 18, TRAINING

Company Policy- The company identifies training needs of all personnel and provides the required training. Personnel performing specific tasks are qualified. Records of personnel qualifications are maintained. Identification of training need and providing training is documented in procedure 4.18, Training.
Training- The company provides new employee orientation training to all employees. Other training is provided as required.
Training Record- The Training Coordinator maintains records of all internal and external training provided to employees in accordance with procedure 4.16, Quality Records.

SECTION 19, SERVICING

Company Policy- Continuous improvement of customer satisfaction is the fundamental core value of our Corporate Mission Statement. The Customer Service department, along with any of the departments, work with the customer to provide a quality product. Procedure 4.19, Servicing, documents responsibilities and rules for providing service to the customer.
Performance and Verification of Service- Any person having contact with the customer performs servicing. When a customer calls with a comment, good or bad, it is written on a customer comment form.
Follow Up- Servicing system data is complied by Customer Service for review by the Management Review Team in Accordance with Procedure 4.1, Management Review.
Records- Records of the Servicing system are retained in accordance with procedure 4.16, Quality Records.

SECTION 20, STATISTICAL TECHNIQUES

Company Policy- Where and when appropriate, statistical techniques are employed to verify the acceptability of process capability and product characteristics. Procedure 4.20 documents our Statistical Techniques system.
Process Analysis and Statistical Sampling- A critical process (as determined by management using the preventive action system) may utilize statistical techniques. Personnel using statistical techniques are provided with charts, tables and other instructions in the use of the techniques.
Records- Records are retained in accordance with procedure 4.16, Quality Records.