Ben Walters - Quality Control Documents

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Quality Control Documents and Technical Writing. I did all the templates, layout, photography and writing. I created over 400 varied documents in my tenure with AVL Technologies.

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Ben Walters - Quality Control Documents

  1. 1. Sample Quality Control Documents Ben Walters Charleston, South Carolina
  2. 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 / Charleston, SC
  3. 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. 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. 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.
  6. 6. Sample Unit Assembly Instructions
  7. 7. Sample Quality Alerts
  8. 8. 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
  9. 9. 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!
  10. 10. Sample Data Storage Documents
  11. 11. 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.
  12. 12. 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.
  13. 13. 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
  14. 14. 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
  15. 15. End of document samples All contents copyright AvL Technologies & Ben Walters benwalters.sc@gmail.com

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