Kidde Aerospace & Defense
4200 Airport Road
Wilson, NC 27896
(252) 237-7004
KEY PRODUCT CHARACTERISTIC NOTIFICATION
Kidde Aerospace & Defense (KAD) is aggressively implementing its variation reduction strategy known as Process Certification, as defined by top level requirements specified in UTCQR-09.1, “Process Certification Requirements”.
Engineering teams have been in the process of selecting Key Product Characteristics per engineering standard KAD 181051, “Engineering Standard Classification of Characteristics”. KAD Suppliers are required to comply with
the above two documents when KAD Engineering flows down KPCs identified on the engineering drawing.
The KPC(s) will be identified on the engineering drawing or on the purchase order. The purpose of this notice is to define the required actions when this flow down occurs. Please call me if you have any questions regarding the features selected and the actions required for their implementation.
Below lists the expectations of any KAD Supplier producing CTQ Parts with defined KPC features:
1) The Supplier must have an approved Process Certification System. Attached below is QAF.0091 Process
Certification System Assessment. Please fill out and return to me within two weeks of receipt of this
notification.
QAF.0091 Supplier Process Certification System Assessment.doc
2) A Process Flow chart must be completed for each process flow that creates a KPC.
3) A Process Failure Mode and Effects Analysis (PFMEA) must be completed for each process that creates or
later impacts the KPC.
4) A Process Control Plan must be created for each KPC feature.
5) For KPC1 and KPC2 characteristics (requiring the collection of variables data):
a. A Gage Capability Study must be conducted for each KPC feature, When Gage Capability Studies
exceed 20% of the engineering tolerance, and then corrective action must be taken to reduce the
measurement system variation.
b. An SPC Control Chart will be utilized as a Level II Mistake-Proofing device to monitor the variation
of the KPC feature in a time-ordered sequence. Actions are to be taken for any data points shown
to be “out-of-control”. Processes are considered to be out-of-control when individual data points fall
outside the control limits or violate common industry-standard rules.
c. The data must be submitted with each shipment but, retained at the supplier facility and made
available when requested.
d. The process is considered certified when:
i. Assignable causes have been identified, documented and removed.
ii. Process inputs and KCs are identified, monitored and controlled.
iii. Documenting a minimum of twenty-five (25) consecutive observations or thirty (30) days of
output whichever is greater, capturing variability associated with step to step, piece to
piece, setup to setup, time to time, and lot to lot variation, with no non-conformances
detected.
e. For processes determined not to be able to achieve a Cpk level of 1.33 or greater, a request will be
submitted to the KAD Supplier Quality Manager for waiver approval/disapproval.
6) For Box0 (zero) characteristics (requiring the collection of attribute data):
Revision: December 2, 2009 Page 1
Kidde Aerospace & Defense
4200 Airport Road
Wilson, NC 27896
(252) 237-7004
a. Data may be taken and archived using a method that suits the characteristic. The data must be
submitted with each shipment but, retained at the supplier facility and made available when
requested.
b. The process is considered certified when:
i. Assignable causes have been identified, documented and removed.
ii. Process inputs and KCs are identified, monitored and controlled.
iii. Documenting a minimum of forty-five (45) consecutive observations or thirty (30) days of
output whichever is greater, capturing variability associated with step to step, piece to
piece, setup to setup, time to time, and lot to lot variation, with no non-conformances
detected.
Your KAD Supplier Quality Engineer will call you in the near future to schedule a Process Control Review (PCR) that is required by KAD Customers. The PCR is to be performed to ensure critical process control and production & manufacturing systems are in effect for the CTQ part you are manufacturing. They will also go over with you the key requirements & contents communicated to you in this letter. Attached below is a copy of the PCR Checklist (QC-0990.2 H). We encourage you to review it and complete prior to being contacted by the Kidde Aerospace & Defense team.
QC-0990.2 H.xls
The attached spreadsheet will help you as you progress through the steps required to certify your process. Again, please do not hesitate to call me for any questions regarding this correspondence.
Regards,
Mike Stone
Supplier Quality Manager
Tel. 252.246.7018
Fax 252.246.7186
Mike.Stone@hs.utc.com
Revision: December 2, 2009 Page 2
Kidde Aerospace & Defense
4200 Airport Road
Wilson, NC 27896
(252) 237-7004
Process Certification Getting Started Spreadsheet
Per the attached Microsoft Excel Spreadsheet entitled “Process Certification Spreadsheet” (QC-0985.4):
QC-0985.4 rev C.xls
STEP 1: Tab #1 illustrates a Process Control Plan. You are required to input the KAD defined KPC(s) in the KAD KPC Database Electronic Control Plan. Feel free to use the one contained in the Getting Started Spreadsheet as a back-up or for any self-selected KPC(s).
STEP 2: Refer to Tab #2 and perform a Gage Capability Short Form Study per instructions on the form.
STEP 3: Refer to Tab # 5 and collect at least 25 consecutive measurements on 25 distinct parts for the KPC feature from the process that generates the feature. Where low volume conditions exist, it is acceptable to infer
process measurements from similar features from similar parts as long as the same process is used to generate those features. Once the data is entered into the spreadsheet, the Cpk will automatically be calculated, as well as the Individuals and Moving Range Control Charts on Tabs #6 & 7.
STEP 4: Analyze the IX-MR Charts on Tabs # 6 & 7 to see if process is in statistical control. If not, ensure proper SPC practice is conducted per UTCQR-09.1. If process is in statistical control, proceed to the next step.
STEP 5: Analyze the Cpk automatically calculated from the data on Tab #5. If greater or equal to 1.33 and the requirements of Step 4 are met, the supplier may discontinue 100% inspection and go to .65 AQL inspections as long as the KPC Type is a “KPC2” or Box 0 (zero). A “KPC1” must always require 100% inspection, even if the
Cpk >/= 1.33 after 25 consecutive measurements. If the Cpk is less than 1.33, continue to Step 6 below. Otherwise continue to Step 7.
STEP 6: Provide a process improvement plan and/or waiver request using the “KPC Management Form” (QC-
0985.5) attached below. The supplier is required to take the necessary action to reduce the variability within the process in order to achieve a minimum Cpk of 1.33. Repeat Steps 2-5.
For “KPC2” type features, do not reduce sampling from 100% inspection sampling until a Cpk of 1.33 or greater has
been achieved. Continue to collect and analyze SPC data at the frequency of 100%.
QC-0985.5.xls
STEP 7: Supplier is mandated to conduct self-assessments of their Process Certification system. Feel free to use the “Process Certification Self-Assessment Form” contained in the “Getting Started Spreadsheet”, Form QC-0985.4,
attached above.
STEP 8: Supplier is to keep completed spreadsheets on file. KAD reserves the right to request copies. These files also provide objective evidence for any future Production Readiness Review or Process Certification Audit conducted at your facility.
Revision: December 2, 2009 Page 3