Samples of some of the over four hundred documents created during my employment with AvL Technologies in Asheville, NC

1. Quality Control
& Document Design
Ben Walters
Asheville, North Carolina

2. QUALITY CONTROL DOCUMENTS
Documents containing extensive data (checklists, carbon reflector specifications
etc.) were created with Microsoft Excel. Quality Alert and instructional documents
containing numerous photographs and annotations were created using Microsoft
PowerPoint. Standard Practice documents for use in-house and externally for
suppliers / vendors were created with Microsoft Word.
Information contained in the enclosed documents is proprietary and is included
to showcase my organizational, design, writing and photography skills. Some
changes have been made to the original documents to protect proprietary
processes and data. Additional documents are available by request.
AvL Technologies in Asheville, North Carolina is the major manufacturer of
satellite antenna positioning units in the United States. Leading clients for the
company include; branches of the armed forces, many agencies within Federal &
State governments and satellite news gathering organizations such as CNN and
ESPN. The following documents are a small representative sample of work I
created while I was with the company.
- Ben Walters / Asheville, NC

3. 1. Assembly Instructions
a) Standard Practices Manual – basic across the board procedures
covering everything from metal preparation, to wiring and painting
b) Supplier / Vendor Standard Practices – supplied to vendors to insure
compliance with AVL standards and reduce the amount of rejected
material
c) Unit Assembly Instructions – unit family specific instructions covering
sub assemblies and final assemblies
2. Unit Checklists
a) Unit Checklists - the cornerstone of quality control for each
manufactured unit
3. Quality Alerts & Job Procedures
a) Quality Alerts - when issues cropped up, Quality Alerts were issued to
each relevant department detailing concerns and the procedures for
rectifying those problems
b) Job Procedures - usually related to manufacturing sub assemblies.
Both Quality Alerts and Job Procedures would be incorporated into
successive revisions of the Unit Assembly Instructions
Documents created fall under six broad categories;

4. 4. End User Material
a) Quick Start Guides – guides for quickly getting a satellite
antenna positioner up in the field, deploying it and locking onto
a satellite signal
b) Case Unit Photographs – laminated photographs showing
proper storage of components in their respective cases
c) Field Repair Procedures – generated for specific clients in
remote areas to direct the repair of satellite antenna positioner
units
5. Data Repositories and Test Results
a) Reflector Data Master – contained test results for all reflector
dishes generated used a Faro Laser Tracker
b) Environmental Test Results – collected data from heat and
load tests of various carbon fiber composites and reflector
configurations
6. Miscellaneous Documents
a) Timesheets
b) Parts requisition forms
c) Labels and signage

5. Sample Software Usage Instructions
These procedures were illustrated using a combination of
screen captures and digital photographs (for image quality,
where more screen detail was needed). They are used as
an adjunct to hands-on training.

12. Sample Unit Assembly Instructions

16. Sample Quality Alerts

17. AvL
Technologies Quality Alert
Distribution:
Operations Manufacturing Mfg. Engineering Assembly Paint
2.0 Meter reflector’s should be numbered as above (clockwise),
as viewed from the back of the reflector. Painted numbers are
placed between the center hub and the seams of the reflector
petals.
2.0 Meter Sectional Reflector Numbering
QA Number: QA-0049
Issue Date: 1/27/06
Expires: 2/27/06
Issued By: B WALTERS
AvL
1
2
3
4
5
6
7
8

18. AvL
Technologies Quality Alert
Distribution: Operations Manufacturing Mfg. Engineering Service Paint
Serial numbers for reflector petals, reflector hub, struts, feed
boom, feed horn & unit should be applied in the same place
and orientation on all 9066 units, except for the vendor specific
labels. Stow & deploy labels should be applied above buttons
as shown .
9066 Label Placement
QA Number: QA-0050B
Issue Date: 3/15/06
Expires: 4/15/06
Issued By: B WALTERS
12 point label 12 point label
12 point labels
P. 1
12 point label
Standard Serial Number Tag
on bottom of unit
GCS only!
Serial number
on front of base
plate
Strut serial
number faces
knurled collar
9 point label
GSI only!

19. Sample Data Storage Documents

20. DIE PLUG BALL
241-051-001-B EL D14 - 1.5 - .218 475S1250 1/8 13716 52 13/16 BA 3-4 <20 Ton
241-050-001-B AZ D14 - 1.5 - .218 475S1250 1/8 13716 53 13/16 BA 3-4 <20 Ton
240-042-001-A EL D14 - .281 478S1500 1/8 13716 74 1/4 BA 3-4 <20 Ton
240-041-001-A AZ D14 - 1.5 - .218 475S1250 1/8 13716 101 7/8 BA 3-4 <20 Ton
181-232-001 AZ D14 -1.5 - .218 475S1250 3/32 13715 75 1/2 BA 3-3 <20 Ton
180-027-003-B AZ D14 -1.5 - .218 475S1250 3/32 13715 60 1/16 BA 3-3 <20 Ton
180-027-001 EL D14 -1.5 - .218 475S1250 3/32 13715 54 9/16 BA 3-3 <20 Ton
128-037-001-A AZ D14 -1.5 - .218 475S1250 3/32 13715 45 3/8 BA 3-3 <20 Ton
128-311-501 D14- .156 A 465S1000 BA 3-2
123-317-301 D14- .156 A 465S1000 BA 3-2
120-072-001 D14- .156 A 465S1000 BA 3-2
075-512-302-A EL (casting) D14- .156 B 465S1000 5/64 13714 38 11/16 N/A N/A
075-512-302 EL (old) D14- .156 B 465S1000 5/64 13714 38 3/8 N/A N/A
127-032-301 POL D14- .156 B 465S1000 1/16 13712 33 3/4 BA 3-2 <20 Ton
120-058-001 AZ D14- .156 A 465S1000 1/16 13712 57 5/8 BA 3-2 <20 Ton
120-054-001 EL D14- .156 A 465S1000 1/16 13712 43 7/16 BA 3-2 <20 Ton
120-053-001 (270) AZ D14- .156 A 465S1000 1/16 13712 48 5/8 BA 3-2 <20 Ton
120-209-001 POL D14- .156 A 465S1000 1/16 13712 31 7/8 BA 3-2 <20 Ton
090-301-001 EL D14- .156 B 465S1000 1/16 13712 36 1/16 N/A N/A
077-125-301 POL D14- .156 B 465S1000 1/16 13712 20 9/16 BA 3-2 <20 Ton
077-124-301 AZ D14- .156 B 465S1000 1/16 13712 36 BA 3-2 <20 Ton
077-123-301 EL D14- .156 B 465S1000 1/16 13712 27 BA 3-2 N/A
075-512-303 POL D14- .156 B 465S1000 1/16 13712 24 3/8 N/A N/A
075-512-301 AZ D14- .156 B 465S1000 1/16 13712 62 7/8 BA 3-2 <20 Ton
075-218-301 EL D14- .156 B 465S1000 1/16 13712 31 15/16 N/A N/A
075-217-301 POL D14- .156 B 465S1000 1/16 13712 22 9/16 N/A N/A
075-216-301 AZ D14- .156 B 465S1000 1/16 13712 62 31/32 BA 3-2 <20 Ton
<20 Ton
Plug & Ball Machined
Open hole to
.078
Open hole to
.078
Cable Drawing
Number
CABLE
Part
Number
EL 5/64 13714 38 5/8
Hydraulic
Force To
Swage
Die Number
Length (")
Ball to Plug Edge
Diameter In
Inches
Part Number
Cable
Assembly Part Number
<20 Ton
Plug & Ball Machined
Open hole to
.089 (#43) x .46 DP
Open hole to
.089 (#43)
AZ 5/64 13714 64 3/4
<20 Ton
Plug & Ball Machined
Open hole to
.089 (#43) x .46 DP
Open hole to
.089 (#43)
EL 5/64 13714 38 3/4
Cable Swaging Chart Sample
Cable Swaging Chart contains parameters for the manufacturing of
stainless steel cables using 20 ton hydraulic press. Used in house for quality control.

21. Reflector Data Master Sample
The Reflector Data Master contains specific parameters for over 250
carbon fiber reflectors. All data collected and recorded using Faro Laser Tracker.

22. Unit Checklists are one of the major quality control measures used within the
company. They accompany each satellite antenna positioning unit during the
entire manufacturing process up through crating and shipping. The checklists
are used to highlight critical areas of concern and differences between similar
units of a particular family. They contain numerous redundancies and secondary
checks.
The checklists also reference the actual assembly instruction procedure for
each unit sub assembly and final assembly. All documentation including
checklists, testing sheets and serial numbers of critical parts were scanned after
the unit was shipped, creating a ready electronic reference file. This file aids in
field repairs and longevity studies for each positioner unit.
Unit Checklists

25. Sample Quick Start Guide
The 9066 unit is a suitcase sized solution for a satellite linkup. Many of these
units have been sold for use within the government agencies for
communications and homeland security purposes. Each unit can replace the
approximately 300 phone line connections and can be used logistically for a
traveling head of state or in disaster situations

32. End of document samples
All contents copyright
AvL Technologies & Ben Walters
benwalters.nc@gmail.com