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This document is for online use. Printed copies are for reference only and considered uncontrolled.

Blue text indicates the changes for this revision.

1. PURPOSE

1.1. This manual defines the essential elements of a supplier quality system and the requirements

of such a system to assure the quality of products supplied to Kaman Air Vehicle,

Maintenance, Repair and Overhaul (AVMRO).

2. SCOPE

2.1. This document provides a guide for AVMRO suppliers but is not intended to supersede any

applicable contract or specification requirement. When conflicts occur, the contract or

specification requirement shall always take precedence.

2.2. Suppliers of proprietary items may be exempt from many requirements within this

document. For specific direction, refer to the Kaman P.O. please contact your Kaman

AVMRO Purchasing representative.

3. RESPONSIBILITY AND AUTHORITY

3.1. The Kaman Quality Manager is responsible for the effective implementation of this procedure.

4. DEFINITIONS

4.1. 3DMBD – Three-dimensional model based definition is the process of developing a

mathematical representation of any surface of an object (either inanimate or living) in three

dimensions via specialized software.

4.2. After-market Supplier – A supplier authorized by a manufacturer to produce, assemble and

sell replacement parts usually due to discontinuation of production. The supplier must identify

such parts so that they cannot be confused for original manufacture.

4.3. Approved Supplier – A supplier who has been evaluated by Kaman and found to have a

quality system capable of providing products, processes or services in conformance with

Kaman or customer requirements.

Title

Supplier Quality Requirements Manual -

Introduction

E-Location

http://www.kaman.com/sites/default/files/

Number Control

SQRM

Process Owner (Dept. & Name)

Wayne Keith. Dept. 500

Approval applies to:

AVMRO ☒ KCC ☐ Both ☐

Appendix

N/A

Date Issued

04/11/97

Rev Level

6

Date Revised

1/8/2018

Date Reviewed

N/A

Flow down From:

Quality Manual sections 7.4.1, 7.4.2 and 7.4.3

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4.4. Broker – An independent distributor that searches the industry for product to satisfy a

customer’s target price and “just in time” requirement.

4.5. Certification of Conformance – All suppliers must enclose this document with product

delivery. As a minimum, this document shall reflect product or service identification,

configuration and process applications. This document must have a company’s officer or

employee official signature and title.

4.6. Certified Supplier – A supplier who has exhibited the ability to deliver product or services to

Kaman, requiring minimal oversight, as reflected in continued high quality rating scores.

4.7. Contract – The purchase order (PO) is the contract between Kaman and the supplier calling

for delivery of product or the performance of services.

4.8. Controlled Process – A process or process sequence that, if changed, could affect design

intent, might affect material structure, mechanical, chemical or electrical properties and cannot

normally be evaluated without destructive testing.

4.9. Controlled Process Change – A change to process previously identified as controlled, a

change from a non-controlled process to a potentially controlled process or a change in the

location (including from one building to another) in which a controlled process is performed on

any component. Temporary changes are included.

4.10. Corrective Action – Prompt action on the part of the supplier to determine root cause in order

to implement timely and positive correction.

4.11. Corrective Action Notice (CAR) – The document used by Kaman for obtaining corrective

action in conjunction with nonconforming material.

4.12. Counterfeit Part – A copy or substitute part lacking legal right or authority for duplication that

is knowingly misrepresented by a supplier.

4.13. Critical Component – A component affecting safety, performance, service life or

interchangeability, designated by Kaman engineering as requiring special controls. This

designation shall be identified on the engineering drawing.

4.14. Customer – The originator of a PO for goods and services supplied by Kaman.

4.15. Designated Inspection Representative – An inspector, employed by the supplier, who is

authorized, by Kaman quality to accept product for Kaman.

4.16. First Article Inspection (AS9102) – A one time verification of a part/assembly to assure the

conformity of each engineering drawing characteristic and B/P note. Actual values shall be

recorded for all characteristics and CMM, digital data; feature chart and test reports shall be

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attached. General notes, such as “complies” or “acceptable” for feature inspections will not be

acceptable.

4.17. Kaman Standard Directive (KSD) 0408 – A Kaman engineering document that lists specific

part numbers and names/addresses of the suppliers who are qualified to manufacture those

parts. Parts identified as KSD 0408 are critical components and require qualification testing

prior to use. They shall not be procured by a source other than that listed in KSD 0408.

4.18. Material Review Board (MRB) - A board, consisting of a representative of the Kaman quality

and engineering organizations, established for the purpose of reviewing and determining

disposition of nonconforming material and ensuring appropriate corrective action.

4.19. Mylar - An un-dimensioned drawing presenting the engineering definition graphically without

the use of numerical dimensions.

4.20. Nonconformance – A process condition or feature that does not conform to the contract,

specification or drawing.

4.21. Nonconformance Control Record (NCR) – A computerized form used to document

discrepant material.

4.22. Objective Evidence – Legible records substantiated by actual test and/or inspection results

that ensure compliance to specification requirements.

4.23. Photo Contact Master (PCM) - Another term used for mylar.

4.24. Vendor Request for Variation – form completed by a supplier or Kaman source inspector to

document discrepant material that cannot be reworked to blueprint and/or specification

requirement before shipment to Kaman.

5. PROCEDURE

5.1. TABLE OF CONTENTS SQRM SECTION TOPIC

Section 1 General Quality System Requirements Section 2 Critical Component Items Section 3 Source Controlled Items Section 4 Serialization Section 5 Statistical Process Control Section 6 First Article Inspection Section 7 Nonconforming Material Control

• Vendor Request for Variation • Nonconforming Material Control Record • Corrective Action Notice • Cause and Corrective Action • Supplier Rating

Section 8 Source Inspection (Kaman or Customer)

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Section 9 Certified Supplier Program Section 10 Model Based Definition (3DMBD) Section 11 Counterfeit Parts Program

5.2. SECTION 1 - Supplier’s General Quality System Requirements

5.2.1. Kaman AVMRO does recognize 3rd party issued system facility registration and

consideration is applied for suppliers maintaining AS9100-ISO900, NADCAP, FAA, EAA,

accreditation in becoming a Kaman approved supplier.

5.2.2. The supplier shall maintain a documented quality system, designed to assure compliance

with all requirements specified by the contract. The program shall ensure:

a. Control of product quality throughout all areas of contract performance.

b. Prevention and ready detection of nonconformance and timely, positive corrective

action.

c. Personnel performing quality functions shall have sufficient, well-defined responsibility,

authority and the organizational freedom to:

1. Identify and evaluate quality problems

2. Initiate and recommend solutions.

5.2.3. Assistance to Kaman personnel – The supplier shall provide:

a. All reasonable assistance, facilities and equipment to assure the safety and provide for

the performance of tasks assigned to itinerant and resident Kaman personnel at the

supplier’s facility.

b. Copies of all documentation, records, etc., as required by contract or upon request by

Kaman or its customer.

5.2.4. Assistance by supplier’s procurement sources – When Kaman personnel are required at

the supplier’s sub-tier, this activity will be coordinated through the supplier’s quality

organization under the cognizance of the contracts department. The supplier shall require

his sub-tier to provide the access and assistance outlined in paragraph 5.2.2.

5.2.5. Manufacturing control – Shall be established and maintained with inspection at

appropriately located points in the manufacturing process. Unless the supplier has

received Kaman approval to perform statistical process control, 100% inspection shall be

performed on all products.

5.2.5.1. Kaman resident/itinerant quality representatives may assist the supplier in fulfilling

contractual obligations.

5.2.6. Written procedures shall be maintained by the supplier pertaining to the following topics:

a. Operating techniques

b. Manufacturing

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c. Processing

d. Preservation

e. Packaging

f. Shipping

g. Calibration

h. Model based definition

i. Inspection and testing

The supplier shall also include the necessary conditions in their procurement documents

to assure that all applicable requirements of the contract are implemented by their

procurement sources. Supplier procedures shall be available for review by Kaman quality

representatives and are subject to disapproval if they do not accomplish their purpose.

When stipulated in the contract, supplier procedures shall be reviewed and approved by

Kaman prior to use.

5.2.7. Design qualification – The requirement for the extent to which design qualification is

required will be established by the purchase order (PO).

5.2.8. Drawing and change control – The supplier shall ensure that the latest applicable drawing,

specification, specification revision levels, technical requirements, PO information and

engineering changes are available at the time and place of supplier’s inspection. All

changes shall be processed to guarantee incorporation at required effectivity points and

records of changes shall be maintained.

5.2.8.1. When manufacturing methods are specified for Kaman designed items or approved

design, no manufacturing changes shall be made unless specifically authorized by a

Kaman PO change.

5.2.8.2. Obsolete and Superseded Specifications – When a drawing specified standard is

subject to a notice of cancellation or supersession and that notice includes some

direction or reference (a “clear path” to a specification to be used in future

acquisition), both the superseding and superseded standards are acceptable for

procurement. If the path is not obviously clear or if questions arise, please contact

Kaman for clarification and direction.

Note: a “clear path” is a discernible direction within a specification, which leads the

reader to conclude by reasonable deduction that one specification replaces the other.

5.2.9. Inspection system – The supplier shall establish and maintain controls for subcontracted

supplies, processes and/or services for suppliers fabricated and processes performed,

within its own facility.

5.2.10. Approved sources – Supplier procured processes or services (e.g., plating, heat treat,

non-destructive testing, etc.), from an outside source shall be provided by only those

sources approved by Kaman or Kaman’s customer when stated on the Kaman P.O.

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Process suppliers who support manufacturers of proprietary items do not have to

be approved by Kaman.

5.2.10.1. The Kaman Qualified Process Supplier List (QPSL) is available on the Kaman website

http://www.kaman.com/aerosystems/solutions/air-vehicles-mro. Click on AVMRO

QPSL to access the list. If you have trouble accessing the system, please contact

your Kaman buyer or the quality department for direction.

5.2.10.2. The supplier is responsible for ensuring that all supplies or services procured from

subcontractors conform to Kaman or Kaman’s customer requirements or approved

alternate requirements at every tier, as required. Compliance to processing and

approval status of sub-tier is the responsibility of the supplier using such

services. Process supplier approvals may change periodically; please check with

respective sub-tier suppliers prior to placing PO for services to assure valid Kaman

approval status.

5.2.11. The selection of sources and the level of control may be adjusted to the nature of the

supplies; however, the supplier is responsible for full compliance with the

specification/requirements and must maintain, subject to Kaman review, adequate quality

control records as objective evidence of such compliance.

5.2.12. Receiving Inspection – The supplier shall subject incoming material to inspection as

necessary to ensure conformance to contract requirements. Objective evidence of such

validations shall be readily available. The supplier shall provide procedures for

withholding from use all incoming supplies pending completion of receiving inspection

activities. Supplies may be released in advance of full acceptance only when positive

controls are in place to assure complete accountability of parts and/or material at all

times.

5.2.12.1. When sub-tier supplier certification and test reports are used for material acceptance

purposes, supplier shall periodically validate accuracy of data on certifications and

reports with respect to services/products/material supplied.

5.2.13. Supplier’s Product Control

5.2.14. Items designated by manufacturer as limited shelf life shall be controlled by date of

expiration. Logs shall be maintained or an otherwise positive system shall be employed

to enable timely capture of items prior to or as they expire. Extensions granted by

manufacturer must be documented. The manufacturer or a qualified lab may also retest

applicable shelf life material in accordance with the manufacturer’s test parameters for the

item. Expired items shall be pulled from service and properly disposed.

5.2.15. The supplier shall continually monitor the process control system to verify the adequacy of

process materials, solutions, equipment and their associated control parameters.

5.2.16. Process controls shall include a high visibility system for:

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a. Identification of process chemicals,

b. Periodic monitoring requirements for solutions and equipment, and

c. Objective evidence of compliance.

5.2.17. The supplier’s method and procedures used to maintain controls and the objective

evidence of control over such processes (including environmental and contaminations

control) shall be in accordance with applicable specifications.

5.2.18. The supplier’s special processes, such as x-ray, ultrasonic, heat treat, plating, etc. (to

include equipment and personnel) shall be subject to approval and certification in

accordance with applicable specifications.

5.2.19. Training – The supplier shall develop, implement and maintain training programs, as

necessary, to assure compliance with applicable requirements for such processes as

soldering, welding, brazing, magnetic particle, fluorescent penetrant inspection, etc.

5.2.19.1. The program shall include initial certification and periodic re-certification of personnel,

in accordance with applicable specifications. Records of training shall include

sufficient detail, which reflects actual training subject and individual’s performance

evaluation.

5.2.20. Documentation – Certification requirements shall be specified on the PO or contract

identifying what material, process or service certifications the supplier shall furnish.

5.2.20.1. When required by PO, the supplier shall maintain and shall so indicate on their

certificate of conformance that actual material, process or services data is retained on

file at their facility. These documents shall be available for review if and when

requested by Kaman or its customer. Reference paragraph 5.2.23.1.

5.2.20.1.1. Certifications of conformance must contain material/service status and have

signatures, title of signatory and dates applied.

5.2.20.2. Submittal of information, other than certification, when required by contract or PO,

shall be made through Kaman Purchasing for transmittal to the affected Kaman

department.

5.2.21. Measuring and Test Equipment – The supplier shall provide for the initial inspection and

periodic calibration of gauges, measuring/ test equipment used for the inspection of parts.

5.2.21.1. Gauges and measuring/test equipment, used for acceptance purposes, shall be

calibrated to standards traceable to the National Institute of Standards and

Technology (NIST). If standards are not available at NIST, industry standards may be

used.

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5.2.22. Tooling – The supplier shall establish a system that provides accountability, identification

and maintenance of tooling.

5.2.22.1. Tooling used as an inspection or test media shall require periodic inspection and/or

calibration. The supplier shall establish the extent and frequency of

inspection/calibration and shall identify tools with due dates for next inspection or

calibration.

5.2.22.2. Tooling and measuring/test equipment furnished to the supplier by Kaman shall not

be altered or modified without prior written approval from Kaman Purchasing. These

instructions also apply to tooling fabricated or procured by the supplier for Kaman

product as part of the contract. User shall maintain a list with calibration re-call

frequency and contact the Kaman buyer when calibration is due; out of calibration

tools must not be used for product acceptance

5.2.22.3. Mylars/Photo Contact Masters shall be inspected for accuracy and condition prior to

use. The supplier shall establish a procedure that addresses the control, usage,

storage, out of tolerance condition recording and operator training for mylar handling.

5.2.23. Records – In order to provide objective evidence of the quality control operations

performed, the supplier shall maintain adequate records of inspections, tests, engineering

change incorporation, serialization, matched part numbers, etc., as required by the PO.

The records required to be maintained by the supplier shall include the following:

a. Evidence of in-process inspection,

b. Evidence of periodic inspection, calibration, control of gauges, measuring equipment

and tooling used as media of inspection,

c. Certificate of personnel, processes and equipment as required by specifications and/or

PO

d. Evidence of FAI

5.2.23.1. Unless otherwise specified by PO, the supplier is required to store and maintain all

inspection and test records of parts and/or assemblies that carry a serial number for a

period of not less than seven (7) years after completion of final settlement of the PO.

After such time, the records shall be offered to Kaman. Reference paragraph

5.2.20.1.

5.2.23.2. Records of parts and/or assemblies that do not bear serial numbers and thus cannot

be subsequently identified shall be kept on file for a minimum of seven (7) years after

completion or final settlement of the PO.

5.2.23.3. All quality records shall be available to Kaman. When specifically required by PO,

records shall be included in a log to accompany the applicable unit to Kaman.

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5.2.24. Preservation, Packaging, Storage and Special Handling – In performance of the contract,

the supplier shall provide necessary protection of all articles to prevent damage, loss,

deterioration or degradation, in accordance with applicable specifications referenced on

the Kaman vendor instructions (VI).

5.2.24.1. The supplier shall provide special handling for articles sensitive to handling damage.

During fabrication and processing, special crates, boxes, containers and

transportation vehicles shall be used as necessary to prevent damage due to

handling.

5.3. SECTION 2 –CRITICAL COMPONENT ITEMS

5.3.1. All critical components require qualification by Kaman.

5.3.2. The requirements of this document shall be enforced whenever KSD 0408 is referenced

on the Kaman drawing, Purchase Order (PO) or Vendor Instruction (VI).

5.3.3. Following initial Kaman qualification, the supplier shall not change

manufacturing method, sequence or site location of a qualified item

without Kaman approval.

5.3.4. Table 1 lists examples of typical processes that may require control. Final decisions

relative to the assignment as a controlled process rest with Kaman. Any question

concerning whether a process requires this control shall be referred to Kaman

Purchasing.

TABLE 1 – CONTROLLED PROCESSES

Casting Forging Drawing Forming Coil Winding Machining Laser cutting, EDM, gear cutting, grinding of surface

hardened parts or high strength parts (HRC 30 and higher), final finishing operations such as honing, lapping and super-finishing

Welding Brazing Shot peening Thread rolling Surface rolling Surface treatments Carburizing, carbo-nitriding, etc. Cold working of Split sleeve expansion

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holes Gear inspection Plating Including copper plating used for masking during

carburizing and other surface hardening processes Coating IVD aluminum, ceramic – does not include paints and

primers Heat treating Normalizing, quench and temper, precipitation

hardening, stress relieving, etc. Hot isostatic pressing Nital etch inspectionAssembling Adhesive bonding Composite part fabrication

5.3.5. The supplier shall define a system for controlling processes, process changes and it shall

address:

a. Responsibility and methods for identifying controlled processes.

b. The method used to obtain Kaman approval of process data including manufacturing

sequence.

c. Coordinating internal approval of process change (controlled and uncontrolled) and

d. Methods to assure changes are not introduced in the manufacturing cycle without

formal approval.

5.3.5.1. The supplier shall maintain records of original Kaman approval of process data and

approval of changes to controlled processes. Process changes not identified as

controlled must be documented for the supplier’s record, but do not require Kaman

approval.

5.3.5.2. The supplier shall prepare and maintain routing sheets for the step by step sequence

of all processes used in producing the component.

5.3.5.3. The supplier shall select controlled processes, using Table 1 as a guide, and identify

these on the routing sheets.

5.3.5.3.1. If only certain portions of such a process are considered controlled, they may be

identified instead of the entire operation.

5.3.5.4. The supplier shall identify any processes deemed proprietary and obtain agreement

from Kaman prior to manufacture.

5.3.5.5. The supplier shall submit to Kaman Purchasing:

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a. Routing sheets with controlled operations identified,

b. Process sheets for each operation identified as controlled and

c. A completed Controlled Process List (CPL), K922. A copy of this form is included

within this document.

5.3.5.5.1. Kaman acceptance of the proposed processing and any requirements for

additional data or changes shall be relayed to the supplier via the CPL.

5.3.5.5.2. The Kaman VI shall define any specific laboratory analyses required from the

supplier or the need for submitting lab samples. With Kaman approval, the

supplier may use samples taken from nonconforming material as long as the

nonconformances do not alter results.

5.3.5.6. The supplier shall complete a First Article Inspection report (FAI) as instructed by

Section 6 of this manual.

5.3.5.7. The supplier shall obtain Kaman approval, via Kaman Purchasing, of any subsequent

change in controlled process sequence, controlled process or supplier of controlled

processes.

5.3.5.7.1. A Controlled Process Change Request (CPCR), K927, shall be submitted to

Kaman before introducing any of the above. A copy of this form will be found at

the end of this section. When submitting process change requests, the supplier

shall identify the old and new processing method in sufficient detail to permit

evaluation of the proposed changes.

5.3.5.7.2. Kaman shall determine the acceptability of the proposed changes and notify the

supplier of this decision on the K927. A copy of the approved change must be

filed with the processing data discussed in paragraph 5.3.5.

5.3.5.8. The supplier is permitted to incorporate changes in processes and sub-tier suppliers,

if said processes are not designated as controlled. The supplier is required to

maintain documentation as specified in paragraph 5.3.5.

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Figure 1 – K922 (CPL

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Figure 2 – K927 (CPCR)

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5.4. SECTION 3 – SOURCE CONTROLLED ITEMS

5.4.1. When a supplier receives a drawing identified as “Source Controlled Drawing”, the

following requirements apply:

5.4.2. The supplier shall provide one (1) reproducible and one (1) reproduced copy of each

assembly, installation and detail drawing, as well as specifications and standards.

5.4.2.1. The drawings shall define:

a. The item and its components as necessary for the fabrication, assembly and

maintenance thereof,

b. Include tolerances and

c. Actual or calculated weight information.

5.4.3. This drawing shall conform to ASME Y14.100 and shall be provided to and approved by

Kaman prior to or concurrent with the delivery of the first production article along with any

applicable technical data.

5.4.4. Without prior Kaman approval, the supplier shall not use any substitute materials in the

product or make any changes to his/her product that will affect interchangeability, either of

the part as a whole or of its components, or the performance of the unit.

5.4.5. The supplier shall submit all revisions to drawings, specifications, standards and other

documents to Kaman prior to, or concurrent with, the delivery of the first article in which

the changes were incorporated. These changes require Kaman approval. Such

documents shall be kept up-to-date by the supplier until delivery of the last article or spare

part to Kaman.

5.4.6. The supplier shall ensure that all name or manufacturing address changes are reported to

Kaman immediately. Product release authority may be withheld pending correction

of this information on the drawing and related documentation.

5.4.7. The supplier shall utilize approved subcontract suppliers that are noted in their approved

supplier listing. Suppliers approved by Kaman may also be used. If any supplier is

specifically named as part of any specification requirement, that supplier must be used.

5.4.8. It is the supplier’s responsibility to maintain correct configuration control of assemblies

and their detail parts.

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5.5. SECTION 4 – SERIALIZATION

5.5.1. Traceability shall be maintained through a system for lot control and serialization subject

to approval by Kaman for materials, parts and assemblies when required by PO.

5.5.2. For non-proprietary parts, when required by PO or VI, serial number assignments must be

obtained through the appropriate Kaman buyer.

5.5.3. Supplier serialization shall be such that the number and/or letter combination shall not be

repeated on another part with the same part number under any circumstances.

5.5.4. Identification shall be maintained during all phases of fabrication, denoting the inspection,

change and/or time limited status of the supplies. This identification may be

accomplished by means of tags, routing, cars, move tickets, tote box cards, stamps

(approved by Kaman) or other normal controls.

5.5.5. Inspection, serialization, identification or acceptance marking shall be placed on the part

in accordance with Kaman requirements and, in a manner that will not damage the part or

assembly.

5.5.6. After serial numbers are assigned to specific product, the serial number must be recorded

on all related certifications, first article inspections, test data, etc.

5.5.7. Products that are subsequently upgraded, reworked or repaired must have the applicable

marking added to the unit serial number, thus indicating the latest configuration of the

product.

5.6. SECTION 5 – STATISTICAL PROCESS CONTROL

5.6.1. Kaman may require statistical process control (SPC) be implemented by a supplier. This

requirement shall be flowed down, via the VI listed on the Kaman PO.

5.6.1.1. The requirements of this document shall be in addition to other purchase order

requirements.

5.6.1.2. Approval of a supplier’s SPC program does not alleviate the supplier of any basic

quality system requirements or engineering/specification standards.

5.6.2. All suppliers must submit their statistical quality assurance program for approval prior to

use. Approval will be based on an evaluation of:

a. The qualification of personnel responsible for application and administration of

statistical quality assurance,

b. Written procedures covering classification of characteristics, application of sampling

techniques, data recording and audit control of this system, and

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c. The comparability of the proposed quality level and control techniques to the

complexity of product and its quality and reliability requirements.

5.6.2.1. When SPC is not a condition of the PO, a supplier may identify process controls to

reduce variability. Kaman believes that defect prevention, rather than detection,

improves customer relations, at the same time saving inspection costs and reducing

scrap/rework.

5.6.3. The supplier is required to report their implementation status when a key characteristic

has been flowed down. The type of information and frequency to be reported will be

identified by Kaman Quality.

5.6.4. The supplier may be required to provide copies of data control charts and process

capability charts.

5.6.5. Special causes of variation must be noted on the control charts and investigated by the

supplier.

5.6.6. The supplier must exhibit a method to study and improve processes and products to

identify causes of variation. (Gage R & R, proper chart selection, etc.)

5.6.7. Key characteristics must be in statistical control. A minimum of twenty (20) points that

represent the production process is required before control limits can be established. A

key will be considered in statistical control if the plotted points do not fall outside the

control limits.

5.6.8. Process capability must only be determined after a process is in statistical control.

5.7. SECTION 6 – FIRST ARTICLE INSPECTION

5.7.1. A first article inspection report (FAI) shall be performed in accordance with AS 9102 when

required by the PO, VI or other contract direction.

5.7.1.1. All engineering drawing characteristics including tolerances and applicable drawing

notes shall be documented on the FAI.

5.7.1.2. Results from inspection of design characteristics shall be expressed in quantitative

terms (variables data) when a design characteristic is expressed by numerical limits.

5.7.1.3. The supplier may use AS 9102 forms or substitute their own FAI record, provided it

meets all the requirements specified in AS 9102.

5.7.1.4. Entries shall be electronically generated (preferred) or manually recorded.

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5.7.1.5. Subcontracted characteristics that are deemed special processes shall be included in

the FAI data and shall be traceable to the subcontractor’s process certification.

5.7.1.6. FAI shall be performed on the categories below:

a. Assemblies

b. Sub-assemblies

c. Detail parts, including castings and forgings

5.7.1.7. The FAI report shall not include any open fields. “N/A” shall be entered in any field

that does not apply to the part being inspected.

5.7.1.8. FAI does not apply to “commercial off the shelf” (COTS), standard catalog hardware,

national/military standard or deliverable software unless the material or products have

been customized to a customer specific designed product.

5.7.1.9. Special tools (jigs, templates, fixtures, etc.) that the supplier fabricated to be used as

a media of inspection shall not be utilized for the FAI unless authorized by Kaman.

The document granting approval must be referenced on the FAI.

5.7.1.10. Unless otherwise specified in the VI, the FAI shall be performed at the frequencies

specified by AS 9102.

5.7.1.11. The FAI for parts with reported discrepancies not re-workable to drawing

requirements shall include the Kaman approved Vendor Request for Variation (VRV)

number.

5.7.1.12. The subsequent lot of parts is to be subjected to a FAI for the characteristics identified

discrepant on the first lot, or until an acceptable FAI is completed.

5.7.1.13. When product has been selected for FAI, it must be clearly identified using tags or

similar method.

5.7.1.14. All completed FAI reports shall be retained by the supplier for a minimum period of ten

(10) years. After that period, Kaman shall be given the option for transfer of

ownership.

5.8. SECTION 7 – NONCONFORMING PRODUCT

5.8.1. Suppliers shall establish and maintain procedures for the identification and segregation of

nonconforming manufactured, procured, contracted and/or subcontracted

supplies/product.

5.8.1.1. In no case, shall the supplier accept or repair and, in turn, ship product that

contains nonconforming characteristics which dimensionally, functionally or

K964-6 Page 18 of 34 02/02/2017

metallurgically violate Kaman prescribed parameters (e.g., Kaman or customer

drawings and/or specifications) as described by the PO.

5.8.1.2. Authorization for disposition of nonconforming product shall be requested through

submission of the Vendor Request for Variation (VRV) through Kaman Purchasing to

the Material Review Board (MRB). Acceptance of nonconforming material is the sole

prerogative of Kaman or its customer. Reference paragraphs 5.8.7 through 5.8.17.

5.8.1.3. Suppliers of proprietary design items are not authorized to conduct material review

action on any nonconformance that will result in a departure from the requirements of

the Kaman or customer “source control drawing” or specification. Such

nonconformance items must have review and disposition by Kaman MRB.

5.8.1.4. If a Kaman supplier discovers that discrepant material has been delivered, the

supplier must promptly notify Kaman in accordance with contractual requirements.

5.8.2. Parts shall be identified as discrepant and segregated from production parts.

5.8.3. Parts that can be reworked to conform to requirements shall be retained by the supplier

for rework.

5.8.4. Reworked parts shall be re-inspected by the supplier and resubmitted to the Kaman

source inspector, if applicable, prior to shipment.

5.8.5. Parts that cannot be reworked to drawing requirements shall be replaced by the supplier

or submitted to Kaman MRB disposition on a VRV.

5.8.6. The supplier shall submit any discrepant part requested by Kaman MRB for evaluation or

disposition.

VENDOR REQUEST FOR VARIATION (VRV)

5.8.7. A VRV shall be generated when a supplier discovers discrepant product prior to shipment

to Kaman that cannot be reworked to blueprint and/or specification requirements.

5.8.7.1. The VRV form can be located at the following Kaman web address:

http://www.kaman.com/aerosystems/solutions/air-vehicles-mro

5.8.8. The supplier shall prepare the VRV using the instructions following this section. Kaman

Purchasing, preliminary material review (PMRB) or MRB may request additional

information upon receipt of the completed VRV.

5.8.8.1. In order to expedite VRV processing, a supplier may communicate, via telephone, e-

mail, etc., instructions for Kaman Purchasing to initiate a VRV.

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5.8.9. The supplier shall check parts in process at their facility to ensure that all similar parts with

the same discrepancy are included in the request.

5.8.9.1. A separate VRV form is required for each part number or dash number.

5.8.9.2. Each discrepant characteristic shall be listed as a separate item on the VRV form.

For example, if the nonconforming part has two different discrepant dimensions, one

would be listed as item A and the other, item B.

5.8.10. The supplier shall complete the corrective action section of the VRV form, designating the

effectivity of such action (refer to paragraphs 5.8 through 5.8.23 for cause and corrective

action requirements).

5.8.11. The VRV form shall be signed by a responsible supplier representative or a designee. If a

designee signs, that person’s name should be co-signed by a supplier authorized

signature.

5.8.11.1. When the person responsible for corrective action is different than the person signing

the VRV form, the identity of the responsible person must also be noted.

5.8.12. Any further work performed on the discrepant material prior to receipt of a formal

dispositioned VRV by Kaman MRB is entirely at the supplier’s risk.

5.8.13. The VRV shall be submitted to Kaman by the supplier, via Kaman Purchasing, prior to

shipment of parts/material.

5.8.14. The original VRV will not be returned to the supplier with a disposition. The Kaman buyer

must transfer the VRV information into the Kaman automated nonconformance reporting

system. This system will assign a new nine digit alpha-numeric identification to the

nonconformance. An example of this form is located at the end of this section. This new

form shall be reviewed, dispositioned by Kaman Quality and Engineering and issued to

the supplier.

5.8.14.1. Upon receipt of the dispositioned form, the supplier shall take action, as directed by

Kaman Engineering disposition, to complete the part (s). The new alpha-numeric

number must be marked on the part (s) and recorded on the packing slip, which

will accompany the shipment.

5.8.14.2. When allowed, bag and tag identification may be substituted for part marking.

5.8.14.3. Discrepant parts, which are to be retained at the supplier’s plant for further

processing, must be identified with the VRV number.

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5.8.14.4. Discrepant detail parts, which through VRV action, are to be incorporated into an

assembly, and shall not be acceptable for use until the VRV number is marked

adjacent to the detail and assembly part number.

5.8.15. If repairs have been performed, a copy of the VRV shall be signed by the supplier’s

inspection or by Kaman source inspection to certify the accomplishment of work in

accordance with the MRB disposition.

5.8.16. When the VRV requires “rework” or “repair”, the detail must be further identified by a

supplier rejections tag that shall be securely attached to the detail prior to shipment. In

cases where progress is recorded in logs, the tag is to be attached to the log. The VRV

number must be entered in the log upon receipt. After complying with the requirements,

the supplier shall insert a copy of the VRV in the log to accompany the shipment of

material/part (s) to Kaman.

5.8.17. When “rework” or “repair” is authorized by a VRV for detail parts not requiring logs, a copy

of the VRV containing the information specified must accompany each shipment.

CAUSE AND CORRECTIVE ACTION

5.8.18. The supplier shall take prompt action to determine cause (s) and to correct conditions

which have resulted or could result in nonconforming supplies or services. This includes

initiating and confirming corrective action with any of his/her procurement sources when

applicable.

5.8.19. The supplier must identify the root cause of the nonconformance and clearly describe

positive corrective action to prevent a recurrence. The effective point of the corrective

action must also be given (i.e., by serial number, lot number, date, etc.) In cases where

fixtures, tooling, dies or patterns are involved, the tool name and number must be

provided. Statements such as “operator cautioned” are not acceptable unless the

corrective action explains the correction of the condition that caused the defect.

5.8.20. The corrective action response will contain:

a. Root cause

b. Clearly stated action that have been or will be taken addressing the cause

c. If necessary, indication of revision to written instructions and training required to

implement changes, and

d. Effectivity of corrective action

5.8.21. Corrective action must be positive and cost effective.

5.8.22. Supporting documentation for any process change shall also be submitted (e.g.,

manufacturing work instruction changes, tool orders, engineering changes, etc.)

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5.8.23. In the event final corrective action cannot be initiated or positively determined within

required response timeframe, an interim reply shall be submitted reporting current status

of the corrective action investigation and the date a firm reply will be furnished.

NONCONFORMANCE REPORT (NCR)

5.8.24. When Kaman identifies a discrepant supplier part or material either upon receipt or later

on in the Kaman manufacturing process, Kaman Quality shall record the information on a

nonconformance report (NCR).

5.8.25. A copy of the NCR shall be included in all return shipments of rejected parts or material.

5.8.26. If corrective action is required, the Kaman buyer will issue the request to the supplier.

CORRECTIVE ACTION REQUIRED NOTICE (CAR)

5.8.27. Kaman Quality may issue a CAR to a supplier when conditions warrant corrective action

based on nonconforming product, unacceptable supplier rating and/or trend analysis.

5.8.28. Suppliers receiving a CAR must respond within thirty (30) calendar days from the CAR

initiation date. The response must address the requirements listed in paragraph 5.8.20

5.8.29. CARs shall be issued through the Kaman buyer.

SUPPLIER RATING

5.8.30. Kaman monitors supplier performance through a supplier performance rating.

5.8.31. The supplier rating is a ratio based on part accepted versus parts inspected.

5.8.32. The supplier rating is automatically calculated monthly, quarterly and annually for each

supplier.

5.8.33. No follow-up action is required for suppliers who maintain a quarterly and annual

performance rating above the current minimum performance goal (95%).

5.8.34. Kaman Quality conducts an analysis of all suppliers whose rating falls below the minimum

requirement.

5.8.35. When a supplier’s rating falls below 95% and the analysis determines a need for

corrective action, Kaman Quality shall provide a CAR to the supplier via Kaman

Purchasing.

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5.8.36. Active suppliers with four consecutive quarterly ratings of less than the minimum

requirement shall not be considered for future procurement without written authorization

from the head of Kaman Quality Manager..

FIGURE 3 – K198 (VRV) FRONT

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FIGURE 4 – K198 (VRV) BACK

Instructions to Complete VRV form

1. Enter discrepant part name

2. Enter discrepant part number

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3. Enter applicable vendor instruction (VI) number (obtain from PO)

4. Enter applicable drawing revision (obtain from VI)

5. Enter parts quantity from PO

6. Enter today’s date

7. Enter applicable contract number (if known)

8. Enter PO number

9. Enter any drawing changes that apply (obtain from PO)

10. Enter lot quantity

11. Enter quantity discrepant

12. Leave blank

13. Enter project number (obtain from PO)

14. Enter applicable PO line item (s)

15. Circle “YES” if this discrepancy has been reported previously, or “NO” if not

16. Leave blank

17. Enter supplier’s name and address

18. List any previous rejection document numbers that have been reported against this part

number

19. Identify KAC buyer’s name

20. List location of discrepancy (drawing locations or reference sketch/photo)

21. Identify if serialized part and list applicable serial numbers

22. Write a brief discrepancy title

23. Provide detailed description on nonconformance. Include drawing/specification

requirement, actual condition and amount of deviation. Be sure to include as much detail

as possible. List each discrepant characteristic separately

24. Identify root cause of discrepancy

25. Provide effectivity of corrective action (in terms of date, s/n, lot #, etc.)

26. Include signature of person responsible for implementing corrective action (if illegible,

please print name also)

27. Provide corrective action initiated to prevent recurrence

K964-6 Page 25 of 34 02/02/2017

FIGURE 5 – KAMAN GENERATED VRV FORM

5.9. SECTION 10 – SOURCE INSPECTION

5.9.1. Requirements for Kaman or customer source inspection shall be specified on the PO

and/or the VI.

5.9.2. An electronic copy of Q.F. 4.1.412 (Source Inspection Request) form is available on the

following Kaman web address:

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http://www.kaman.com/aerosystems/solutions/air-vehicles-mro

5.9.2.1. The supplier shall complete the form and submit to the e-mail address listed on the

source inspection request form. (KAS-Supplier.Support/Svs@Kaman.com)

5.9.2.2. Instructions to complete this form are located at the end of this section.

5.9.3. The supplier shall complete final inspection and/or tests and prepare all contract required

documents prior to submission to the Kaman source inspector, quality representative prior

to shipment.

5.9.4. Kaman shall make every attempt to support product inspection within five (5) working

days after receiving the request.

5.9.5. Verification of source inspector assignment will be made via a return e-mail, fax or

telecom to the point of contact identified on the request.

5.9.6. Kaman may waive the source requirement and the waiver notification shall be provided to

the supplier via a completed Q.F.4.1.412. The supplier must ensure that a copy of the

waiver accompanies the product shipment.

5.9.7. The supplier shall provide the source inspector with:

a. Required tools, gauges and any necessary personnel

b. Applicable certifications and documents (PO, VI, work instructions, test specifications

and test data)

c. Adequate lighting, ventilation and work space

5.9.7.1. If any of these items are not available, the source inspector shall work with the

supplier to resolve any issues.

5.9.7.2. In process source inspected parts must be properly identified with the required

inspection acceptance status. The Kaman source inspector shall complete an

inspection report (K750) identifying the status of inspections accomplished. Copies of

this inspection report shall be provided to the supplier and must be included with the

supplier’s certification package and product shipment to Kaman. A copy of this

document is located at the end of this section.

5.9.8. Product requiring Kaman source inspection, delivered without evidence of source

inspection, may be rejected.

5.9.9. Applicable certifications and document packages are to be maintained on file at the

supplier’s facility and are to be made available to Kaman within two (2) business days if

requested.

K964-6 Page 27 of 34 02/02/2017

FIGURE 6 – Q.F.4.1.412 (SOURCE REQUEST FORM)

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Instructions to Complete the Source Inspection Request form

Enter the information in each cell as described below:

1. Your company name

2. Your supplier number, located on the Kaman PO

3. Your street address, city and state

4. Phone number of your quality point of contact supporting the product inspection

5. E-mail address for item 4

6. Kaman buyer’s name listed on the Kaman PO

7. Name for item 4

8. Part name (abbreviation is accepted)

9. Part number as shown on PO

10. Quantity of parts available for inspection (can be more than PO requirement)

11. Kaman PO number

12. Project number that is listed for each PO line item, usually abbreviated: Proj: XXXX

13. Date product is ready for source inspection

14. Indicate type of required inspection (FAI, in process or final)

15. Include any other relevant information

Note: Save as a Word document and forward to KAS-Supplier.Support.Svs@Kaman.com

K964-6 Page 29 of 34 02/02/2017

FIGURE 7 – K750 (SOURCE INSPECTION REPORT)

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5.9.10. SECTION 10 – CERTIFIED SUPPLIER PROGRAM

5.9.10.1. The certified supplier program authorizes suppliers to inspect and ship

material/supplies on behalf of Kaman. This authority is granted primarily to suppliers

who have exhibited high quality rating scores.

5.9.10.2. Kaman Quality, Purchasing, source inspectors or the supplier may suggest potential

candidates for the certified supplier program.

5.9.10.3. Two levels of certified supplier exist:

1. Certified supplier – a supplier who shall process and deliver material directly to a

Kaman facility using the supplier quality system as sole support of product inspection.

2. Designated Inspection Representative (DIR) – a supplier who will have specific

inspectors assigned Kaman inspection stamps. The DIR will perform product

inspections on behalf of Kaman Quality.

5.9.10.4. The supplier shall submit their implementation procedure to Kaman that contains the

minimum requirements listed below:

a. Evidence that only qualified personnel is eligible for assignment as a DIR.

b. Only a Kaman approved DIR possesses and uses a Kaman acceptance stamp.

c. Parts requiring FAI may only be shipped after the FAI has been accepted by Kaman.

d. The DIR shall review certifications.

e. The DIR shall be responsible for verifying process operations performed by sub-tier

suppliers.

f. Issues relative to quality shall be reported to Kaman receiving inspection.

g. All of the above and any relative DIR function shall be subject to audit verification.

h. Notification of any previously assigned DIR inspectors’ change in employment status.

5.9.10.5. The supplier shall submit resumes of prospective DIR inspectors to Kaman. The

resume must include all available information pertinent to the education and

experience relative to the type of work the inspector shall perform.

5.9.10.6. After an inspector has been accepted by Kaman for the DIR program, he/she shall

receive training by a Kaman representative.

5.9.10.7. Following approval, Kaman shall issue a Kaman final acceptance stamp to the

approved DIR.

NOTE: Only a Kaman approved DIR shall be assigned a Kaman acceptance stamp.

It is the responsibility of the DIR to maintain control and prohibit unauthorized use of

the inspection stamp.

5.9.10.8. Any change in employment status of the DIR shall be reported immediately to Kaman.

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5.9.10.8.1. The DIR shall be responsible for the following:

a. Verifying process operations performed by sub-tier suppliers and assures that only

Kaman or customer (when required by VI) approved process sources are used.

b. Reviewing all certifications for completeness, accuracy and acceptability

c. Inspecting to ensure all drawing and specification requirements are in accordance with

the VI, PO and manufacturing instructions.

d. Ensuring that parts requiring FAI are not shipped to Kaman until the FAI has been

approved by Kaman Quality personnel.

e. Applying his/her stamp to the certificate of conformance, applicable work order and

inspection records to ensure product/service compliance

f. Reporting all product related quality issues to Kaman

g. Verifying that all supplier’s packaging is per appropriate specifications

h. Assuring that his/her DIR stamp is under his/her control at all times and is being used

properly.

5.9.10.9. The DIR is subject to periodic audits by Kaman personnel. Discrepancies discovered

during Kaman audits of DIR inspected items shall be investigated and appropriate

follow-up action shall be implemented. If the investigation warrants, Kaman will

submit a CAR to the supplier for action (reference section 7 of this manual for specific

instructions regarding non-compliances and corrective actions).

5.9.10.10. In addition, a DIR supplier must also maintain a continued quality performance rating

that meets or exceeds 95% (parts accepted versus parts inspected). If the supplier’s

rating slips below that threshold, Kaman may implement one or more of the following

actions:

a. Tighten the frequency of audits

b. Impose additional inspections

c. Issue a CAR

d. Perform an on-site visit of the supplier’s facility

e. Rescind the DIR approval.

5.10. SECTION 10 – MODEL BASED DEFINITION (3DMBD)

5.10.1. Suppliers providing inspection and manufacturing support for product derived from

electronic media, i.e., model based definition, computer aided engineering (CAE), and

etc., shall maintain a control system necessary to meet the minimum requirements

necessary to support the contract.

5.10.2. When the contract does not flow product specific requirements for this product group, the

supplier shall comply with requirements included in this document.

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5.10.3. Suppliers shall develop a quality assurance plan (QAP) that shall contain definition control

for:

a. Electronic data acquisition through a secure site

b. Configuration control and incorporation of engineering changes

c. Software translation process and verification

d. Electronic data interpretation

e. Software security

f. Control and flow down of datasets to sub-tier suppliers

g. Schedule of minimum points to define features inspected on CMM

h. Product manufacturing

i. FAI

j. Product inspection

k. Computerized measurement system support

l. Tooling

m. Operator training

n. Processing and reporting of nonconforming material

5.10.4. Suppliers shall submit their QAP to Kaman for initial review and acceptance prior to

delivery of production material. Changes to the approved plan shall not be implemented

until submitted to Kaman for review and acceptance.

5.10.5. When required by contract, Kaman shall submit their supplier’s QAP to the customer.

5.10.6. Kaman shall audit the supplier’s facility to verify capability and control for 3DMBD product

support.

5.10.7. Any supplier, using sub-tier sources for manufacture and process support, shall ensure

compliance to these requirements by on-site audits and supplier support as needed to

meet contractual requirements.

5.10.8. When required by contract, supplier sub-tier compliance shall be submitted to Kaman.

5.10.9. When source inspection is invoked by contract, the supplier shall provide Kaman and

Kaman’s customers access to product, tooling, electronic data, drawings and QAPs

necessary to validate compliance to contract.

5.11. SECTION 11– COUNTERFEIT PARTS PROGRAM

5.11.1. The supplier shall implement a system that controls procurement of counterfeit material

and provides for risk mitigation in accordance with SAE AS5553.

5.11.2. If a part is not available from an authorized distributor/manufacturer, it may be purchased

from the following sources, if approved by Kaman. Reference additional requirements for

electrical material in paragraph 5.12.7.

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a. After market suppliers

b. Brokers

c. Customers with excess inventory

d. Independent distributors and dealers

e. U.S. Government stores

f. Non-franchised distributors

g. Internet sources

5.11.3. The supplier shall require actual manufacturer’s certifications be supplied with all

purchases.

5.11.4. The supplier shall assure that the PO includes the following requirements:

a. Complete traceability of the product

b. Tests and inspection necessary to assure pedigree of material

c. Level of quality management system

d. Required documentation and certification

5.11.5. The supplier shall verify that material is received with manufacturer’s certifications, check

for manufacturer’s markings on material and inspect for suspicious markings,

repackaging, labeling and visible product defects.

5.11.6. The manufacturer’s certification of conformance must include the following to Kaman:

a. Manufacturer’s name, address

b. Part number and dash number

c. Batch identification such as codes for date, lot, serialization, etc.

5.11.7. Suppliers who receive approval to purchase from companies, listed in paragraph 5.11.2,

must have all electrical characteristics verified by an independent testing facility. This

testing shall be accomplished on 100% of the material. No sampling plan is allowed.

5.11.8. These testing results shall be included with the certification package and provided to

Kaman.

5.11.9. Under no circumstances, should any defective or counterfeit part be provided to Kaman.

6. REFERENCE DOCUMENTS

6.1. Purchase Order (PO)

6.2. Vendor Instruction (VI)

6.3. KSD 0408

6.4. K922, Controlled Process List (CPL)

6.5. K927, Controlled Process Change Request (CPCR)

6.6. ASME Y14.100

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6.7. K198, Vendor Request for Variation (VRV)

6.8. Nonconformance Report (NCR)

6.9. Corrective Action Request (CAR)

6.10. Q.F.4.1.412 (Source Inspection Request)

6.11. K750, Source Inspection Report

7. CONCURRING AREAS/APPROVALS

7.1. Wayne Keith, Quality Manager – Approved via email on 01/09/2018

Document Revision History

Rev Description of Change Date Released Training

Required? (Y/N)

0 Original Release 04/11/97

7 Complete rewrite – combined all previous chapters into single document 5/15/2018 N