QUALITY ASSURANCE PLAN

1.0   INTRODUCTION
  THE FIRE PUMP CO. has developed a minimum level of design QUALlTY that exceeds that of this industry and an inherent product QUALITY that transcends conventional practices and in all cases meets and/or exceeds applicable codes and standards. THE FIRE PUMP CO. will not attempt to meet customer requirements that fall below these minimum established QUALITY levels. However, for each deviation below these limits; an alternative upgrade will be included in our proposal in the best interest of QUALITY. THE FIRE PUMP CO. will not warrant fabrications that by third party direction do not meet minimum established "FPCo" QUALITY levels.
2.0   SCOPE
  This document outlines the requirements for quality assurance as well as the management system and techniques utilized for continuous improvement of the QUALITY process in all phases of THE FIRE PUMP CO.'S operation.
3.0 QUALITY SYSTEM REQUIREMENTS
3.01 The definition of Quality in the view of the FPCo is more than: 
1) Welding and painting done to industry acceptable procedures, 2) testing of individual components (that are warranted by their OEM), 3) passing inspection by individuals who have no idea of the benefits of the functions designed into the equipment. Quality is the "performance excellence" of the design innovations, plus the resulting reliability and low maintenance necessary to allow that kind of operation.
3.1 Management Responsibilities
3.1.1 Quality Management and customer satisfaction are ultimately the responsibility of the MANAGING DIRECTOR and the ENGINEERING/QUALlTY ASSURANCE MANAGER (QAM).
3.1.2 The goal of our QUALITY MANAGEMENT SYSTEM is to meet and exceed the expectations of our customers. This is achieved through continuous analysis of equipment performance during factory test, FPCo final article test and the field operation. Quality is maintained and improved by selective award and review of contracts to the FPCo's "Vendor Manufacturing Family (VMF)" that supply equipment, the assembly process, and as well as field performance.
3.2 ORGANIZATION
3.2.1 We will utilize the team concept of the natural work group forming a specific Quality Action Team (QAT) to identify causes of product variation and nonconformity. The QAT will be chartered by the QAM to identify non compliance to FPCo craft and design requirements and to provide solutions for improvement at these levels specifically, as well as those of the specific job. The QAT will be comprised of at least a two-member work group, and will be chartered by the QAM to perform a specific task.
3.2.2 The QAM's responsibility is to oversee, direct and improve the quality management program, and to assist the QAT in establishing higher quality vendor sources. The QAM will utilize all available resources to ensure conformance to design requirements and specifications and all other applicable codes, standards and regulations.
3.2.3 Management will conduct reviews periodically to ensure the effectiveness of our quality process and progress towards continuous improvement.
4.0 CONTRACT REVIEW
4.1 The FPCo management team reviews all customer contracts/purchase orders. The review subsequently assures that the following conditions are met:
4.2 Product requested is consistent with our quotation.
A) Quantity requirements are in accordance with our quotation.
B) Conform to delivery requirements.
C) Conformance to terms and conditions of sale (i.e. freight terms. Payment terms, etc.)
4.3 If any of the client's contract requirements are not met by our offering, variations in conformance are noted in the quotation, and the customer shall be contacted to resolve the discrepancies.
5.0 DESIGN CONTROL
5.1 THE FIRE PUMP CO. shall establish and maintain only those procedures deemed necessary to control the design of the product in order to ensure that the specified/quoted requirements are met.
5.2 For products requiring special design and/or engineering, management selects qualified staff or contract personnel to provide the service or design the specific assembly. All management and staff personnel have access to current national codes and standards.
5.3 Design drawings are prepared using AutoCAD, when specifically required by the client.
5.4 Management will review the product specification in order to define any errors or omissions. If any are noted, they are documented and clarified with the customer before the design can be completed.
5.5 A review is held to confirm that the design complies with the customer's purchase order and/or all applicable codes and standards. (See Paragraph 8.2)
5.6 All design changes are confirmed in writing and maintained in the job/customer file.
6.0 DOCUMENT CONTROL
6.1 All contacts/purchase orders are assigned a job number. This number shall appear on all correspondence and all other documents unique to the particular job, and shall be maintained in the job/customer file.
6.2 The QAT will in the normal course of the continuous improvement activities, periodically review all methods and procedures in use by their department and make necessary revisions as required.
6.3 All control documents (vendor purchase orders) generated by the FPCo will be reviewed for accuracy and maintained in the job/customer file.
7.0 PURCHASING
7.1 Vendors will be selected based on their ability to conform to the quality standards of the FPCo.
7.2 Purchasing QAT shall identify all key suppliers and communicate to these suppliers the need for conformance to quality requirements. These key suppliers are members of the FPCo's VMF. Their long relationship and continued effort to supply only quality materials is the only reason they continue to be a FPCo vendor. In addition to being monitored by our Purchasing QAT as stated, additional areas of performance required are: on time delivery performance, conditions of packages upon receipt, accuracy of packing lists and invoices, technical assistance, quality of products, and competitive pricing, etc.
7.3 All purchase orders shall contain the information necessary for the vendor to provide the equipment and/or service required. This shall include, when applicable: vendor part numbers, descriptions, specifications, drawings, compliance to applicable codes and standard packaging instructions inspection requirements, and all other information deemed necessary to provide the finished product.
7.4 The Purchasing Department will verify, through inspection of materials received, as described by product purchase orders, the conformance to quality requirements. Final verification is completed through the final article function tests conducted at the completion of the assembly.
8.0 PROCESS CONTROL
8.1 The design and production of the types of products furnished by the FPCo will comply with the customer's requirements limited only by codes and FPCo standards.
8.2 The following codes and standards are used in part, or as applicable, as a guide for the quality of production and workmanship for the various products produced:
A) National Fire Protection Association (NFPA)
B) American National Standards Institute (ANSI)
C) American Welding Society (AWS)
D) Underwriters Laboratories Inc. (UL)
E) Steel Structure Painting Council (SSPC)
F) National Equipment Manufacturers Association (NEMA)
8.3 All process control is the responsibility of the respective vendor/manufacturer. Documented procedures whatever the form is the prerogative of the individual manufacturer. The fabrication and assembly process quality is maintained based on the skill of the individual craftsman and/or vendor and not on a procedure written for a specific discipline.
9.0 INSPECTION AND TESTING
9.1 All incoming raw materials or finished products from suppliers are carefully inspected for item description, quantity and damage. Only those items, which meet the requirements of the customer and the FPCo, are allowed for final product assembly.
9.2 During the production process, all assembly items are matched to the design requirements. Deviations are approved by the project manager and documented. As applicable, the customer is required to approve changes.
9.3 Any product, which does not meet the requirements, is removed from the assembly process. Depending on the item, the option for modification, repair or replacement is directed to the project manager.
9.4 Corrective actions are documented and are discussed with production personnel and management to minimize possible re-occurrence.
9.5 All equipment shall receive a final inspection and function test if applicable. Function test criteria will be amended based on equipment type and agreed upon customer requirements.
9.6 Only customer required inspection records and test certificates shall be maintained in the job/customer file.
10.0 INSPECTION, MEASURING AND TEST EQUIPMENT
10.1 Test equipment used by the FPCo's vendors in their production process is calibrated as required depending on the equipment and the code compliance.
10.2 Calibration certificates are provided only as specially required by the client request. The calibration certificate for the latest calibration will be provided as required by said request.
11.0 INSPECTION AND TEST STATUS
11.1 The primary components; pump, gear, engine and controller are factory tested to comply with Hydraulic Institute, AGMA, NFPA and individual manufacturer's standards. In the event UL/FM labels (certification) are required, identification methods consist of, but are not limited to, metal stamps, tags, labels and inspection test records. Tests are conducted as defined by the vendor P.O.s as per the ITP attached. All specified inspection and test records and/or certificates are maintained in the job files for inclusion in the job data manuals.
12.0 CONTROL OF NON-CONFORMING PRODUCTS
12.1 Products identified as not in compliance with specifications or FPCo vendor P.O.s will immediately he removed from the assembly process.
12.2 Standard products found to be defective or not in conformance will be returned to the vendor for replacement or repair. Additionally, the Purchasing QAT shall note the discrepancy in the vendor file. In the event the vendor cannot comply with the FPCo requirements, an alternate vendor will be selected to meet these requirements.
12.3  Fabricated items found to be defective or not in conformance will be replaced or repaired under the direction of the project manager. The cause for the variation shall be determined and if necessary the drawings changed to eliminate future defects.
12.4 It is the responsibility of all THE FIRE PUMP CO. employees and members of the "VMF" to assure that our customers receive the highest quality products and services. All areas of non-conformance to requirements will be addressed and resolved with the appropriate vendor. The QAT and the QAM are empowered to develop action plans to improve the process, and when appropriate, implement their plans.
13.0 HANDLING, STORAGE AND DELIVERY
13.1 Customer requirements for handling, storage and shipment will be noted in the contract review. If the FPCo cannot comply with customer's requirements the customer will be notified and alternative methods of storage, handling and delivery will be approved prior to order entry.
13.2 Handling and storage of all incoming raw materials and finished products shall be consistent with manufacturer's recommendations to prevent damage and/or deterioration.
13.3 The Project Manager or the Purchasing Department will communicate instructions for special handling and storage requirements to the shop personnel in writing.
13.4 Special packaging and shipping requirements will be communicated in writing to shop and shipping personnel and documented in the job file. When applicable, the instructions shall also be printed on all shipping papers and documents.
13.5 All hazardous materials will be properly labeled, packaged, and shipped in accordance with appropriate codes and standards.
14.0 QUALITY RECORDS
14.1 Records pertinent to The FPCo quality management system and continuous improvement process will be maintained by the (QAM).
14.2 The Purchasing Manager maintains necessary records from primary suppliers on their quality management system and availability of evidence of such a system.
14.3 Quality assurance inspection reports, test certificates and other quality related data pertinent to a specific job or contract shall be available from primary vendors only.
15.0 TRAINING
15.1 New FPCo employees will be properly trained in the area that they will be working before any is to be performed. The department manager is responsible for documenting satisfactory completion of the training.
15.2 Department managers will conduct regularly scheduled training sessions in an effort to improve skills in all areas of our operation.
15.3  It will be the responsibility of management to stay current with any changes to industry standards, State or Federal Laws, or manufacturer's recommended procedures and train the appropriate personnel which the changes would affect.
15.4 Employee Personnel files will be maintained to record any individual training received.
16.0 PURCHASE ORDER PROCEDURE
16.1 All material and services are issued a purchase order defining specifically the item required. Each order is assigned a number that is comprised of the job designation and the commodity code number i.e. the pump is 01, the gear is 06, the engine is 08 and the controller is 16. The commodity code is always the same.
16.2  The P.O. includes the description of the commodity, services or tests and the factory test certificates that are required and available. i.e. pump performance or hydro, engine test letter, vessel hydro et al.
16.3  The P.O.s are issued; the original to the vendor, copies with prices to accounting and to the job file, copies without prices to the assembly shop. Unpriced copies w/an ITP are issued to the client when required.
16.4 The assembly shop copies are used to verify what each purchased item is visually what was ordered and undamaged through shipment.