Smith, John e: AXH-123 Details: During final test of AXH-123, poor soldering was noted on the following components: - Resistors R1, R2, R3 - Capacitors C1, C2 The solder joints were dry and cracked. This is likely caused by insufficient solder being applied during wave soldering. Corrective Action: The wave soldering process was reviewed and the following changes implemented: - Solder pot temperature increased by 5 degrees C to improve wetting - Dwell time over the wave increased by 1 second to allow better filling of joints - Solder paste application checked to

1. MARCONI AUSTRALIA
ENGINEERING
QUALITY ASSURANCE MANUAL
The documents in this manual are specific to the
Marconi Australia Engineering Quality, but function
within the framework of the company Quality
Management System.
Where a procedure or form in the company QMS
conflicts with the Engineering QA Manual, this manual
takes precedence.
Individual documents in this manual are version
controlled, but the manual itself (as a collection of
documents) is not. These documents are held on the
Marconi Global Intranet and local Quality Worksite.
Printed copies of the documents are uncontrolled.
6/14/2014
Confidential Page 1 14/06/2014

2. 1 SCOPE
This document is part of the Marconi quality management system. It has been primarily
produced to provide guide to Engineering (product specific) quality assurance
documents, processes, role and responsibilities and how they apply to the Region –
Australasia.
2 INDEX
Confidential Page 2 14/06/2014

3. DOCUMENT NUMBER COMMENT
Primary Documents
Engineering QA Manual Australia Issue 01 This document – MA Worksite
Quality Manual QMS100 Global Intranet
Product Recall Policy QMS200 Global Intranet
Quality Policy Statement quality
policy109f
727512b.
pdf
This document – MA Worksite
Non-conformance Reporting Processes
APAC Customer Complaints Process (CC) MA Intranet
Logistics RMA Process (RMA) MMS Intranet
Customer Supply Issue Process (CSI) MMS Intranet
General
Order Management & Planning QMS201 Global Intranet
Store
Stock Quarantine – SAP location 1RQA 1RQA SAP Quarantine location for products
(It is a separate storage location within
SAP & the warehouse).
Forms
Product Quality Technical Report 90714 MA Worksite
Refer
Annex A
Refer worked example in Annex A.
Customer Complaint Alert Form MA Intranet
Acceptance of Customer Complaint MA Intranet
Corrective Action Process MA Intranet
RMA Form (Repair Service Request) MA Intranet
Websites
MMS Intranet Link http://mmsintranet/Mmsintranet/Call
%20logging.htm
MA Intranet Link http://intranet.marconi.com.au/
Product Alerts Link http://cvapps01.marconicomms.com/apps/
BIS/SixSigma/Alerts_comms.nsf/df42a5c6
6d6c33b6802568ef00506564?
OpenView&Start=1
Product Bulletins Link http://www-comms-
cov.intranet.marconi.com/Home_User/ON
_NM/SDH_and_other_Transport/Product_
Bulletins/index.htm
Global Quality Intranet Link http://www-comms-
cov.intranet.marconi.com/globalquality/
Global Customer Complaint Intranet Link http://www-comms-
cov.intranet.marconi.com/opsukqse/inform
ation/QualityForms.html
Confidential Page 3 14/06/2014

4. DOCUMENT NUMBER COMMENT
WorkSite MP Link http://worksite.ap.marconi.com/worksitem
p/index.jsp
3 AMENDMENT RECORD
Version DETAIL (incl files affected, and Change Request form reference) DRAFTER
/ DATE
AGREED BY
/ DATE
Draft Original S Hackett
9 Jan 2006
T Dudley
9 Jan 2006
01 Updated weblinks 15 Mar 2006 15 Mar 2006
4 ROLES & RESPONSIBILITIES
The following people manage Quality in Australasia:
Role Name
Engineering Quality Manager – Level 3 Simon Hackett
Warehouse Manager – Level 2 Tom Evans
Production Manager – Level 2 Peter Witte
Quality Engineer – Level 1 Ross Finlay
Quality Assurance Representative (ISO Quality) John Mason
OH&S Jim Simpson
Confidential Page 4 14/06/2014

5. 4.1 ENGINEERING QUALITY ORGANISATION CHART
This Organisation Chart indicates who is responsible for Engineering (product specific)
quality assurance.
Level 1 – Individual workers are responsible for quality and quality management.
Level 2 – Management is responsible for supplying workers with the correct tools and
training.
Level 3 – Is responsible for Engineering Quality Control.
4.2 GLOBAL QUALITY CONTROL REPRESENTATIVES
The following shows the Global QMS Representatives; at the time this document was
published. Current and up to date information is maintained on the Marconi Global
Intranet.
Division / Location Representative Name
UK New Century Park - Product Improvement Manager Paul Betteridge
+44 247 656 2000
Italy Genoa - Product Improvement Manager Roberto Feri
+39 010 600 3371
Confidential Page 5 14/06/2014
Engineering Quality
Manager
Warehouse Staff
Production
String Test Engineers
Project Managers Customer Services
Managers
Production Manager
Warehouse Manager
Quality Engineer
PRODUCTS
CUSTOMERS
Level 1
Level 2
Level 3
GLOBAL QUALITY CONTROL

6. 4.3 14 POINT QUALITY PLAN
The goal of Marconi’s Regional Quality Organisation is to satisfy the needs and
expectations of our Customers by involving every employee in the supply chain.
All employees involved in the delivery of products and services to our Customers need to
be conscious of quality. The following outlines 14 Points relating to Quality which assist
focus the mindset of staff in achieving this objective:
(Adapted from Deming Quality Policy)
1. Commitment to continuous
improvement of product and services.
2. Find problems & Act. Adopt the new
philosophy. We can no longer live
with commonly accepted levels of
delays, mistakes, and defective
workmanship.
3. Defect prevention over defect
detection and certainly not correction
(rework).
4. Consider quality of product, not just
price.
5. Train and educate quality principals. 6. Consistent quality message through
the organisation.
7. Coaching/support not just supervision. 8. Drive out fear of improvements.
9. Remove barriers that hinder quality
improvement.
10. Avoid unrealistic targets and slogans
asking for new levels of productivity
without providing methods.
11. Remove barriers that prevent
employees having pride in their work.
12. Eliminate work standards that
prescribe numerical quotas.
13. Constantly improve. 14. Break down barriers between
departments and create
organisational structure to support
these points.
Confidential Page 6 14/06/2014

7. 5 ENGINEERING QUALITY ASSURANCE
5.1 FACTORY ACCEPTANCE
All products are firstly subject to the control and monitoring activities performed by the
manufacturing quality function. Formal quality release points exist at:
 The end of the PCB assembly process, i.e. IQC - Intermediate Quality Control,
where conformance to relevant specifications and standards of workmanship are
verified.
 Immediately before the release of the completed item into packaging, i.e. FQC -
Final Quality Control, where conformance to functional and workmanship
requirements are verified.
The routine factory acceptance and release of product required for any contract is
qualified by the issue of a Certificate of Conformity for each consignment of product for
delivery.
Customer acceptance testing is outlined in Customer specific contracts within the
Region. The specifics of Customer acceptance tests are agreed by Commercial, Project
and Account Managers prior to the award of each contract.
5.2 INSPECTION AND TESTING
Procedures, instructions and associated specifications are used to ensure that formal
inspection, testing and quality assessment is undertaken at defined points in the process
to ensure product conformance.
Documented procedures define the inspection and test criteria for each product. These
further identify the equipment required to undertake such activities. No product will be
released until all the specified activities have been satisfactorily completed.
Functional tests are performed automatically utilising specialised test equipment and
dedicated in-house test software designed to fully verify product functionality.
Consequently, it is not company policy to record the actual values of all test results
obtained. However, it is emphasised that for acceptance, all test results shall be within
limits prescribed in the approved test applications.
5.3 CALIBRATION
All measuring and test equipment used to verify performance is calibrated at regular
prescribed intervals to ensure the correct level of accuracy is maintained. All equipment
and standards used for the purpose of calibration are traceable to national and
international standards as appropriate and relevant.
5.4 NON-CONFORMING PRODUCT
All non-conforming product identified at any stage during the manufacturing cycle will be
segregated from conforming material and will be subject to review pending a decision on
its future (i.e. rework, concession, scrapped, etc.). Data concerning the non-conforming
product is regularly analysed with the results distributed to relevant personnel to ensure
corrective and preventative action is effective.
Non-conformities detected during internal audit/management review activities are
documented in formal audit reports with the resulting corrective actions closely monitored
to ensure satisfactory resolution of the immediate problem, and that where relevant
procedures and processes are amended to prevent recurrence.
Confidential Page 7 14/06/2014

8. 5.5 HANDLING AND PACKAGING
Procedures and processes are in place throughout the manufacturing cycle to ensure
that the integrity of the product is not compromised during any handling or storage. This
includes ensuring electro-static discharge precautions are taken into account at all
stages.
Final packaging is designed to ensure that the product is protected from all types of
climatic and transit damage and is received by our customers in first class condition. The
specifications for the materials and methods used in packaging the product are defined
for each type of product and climate.
5.6 BUILD STATUS CONTROL
The company has a policy of continuous improvement and will enhance its products as
and when it considers it appropriate. The build status of equipment to be delivered in
support of any contract will be that applicable at the time of supply.
Engineering information is used by manufacturing to ensure that the build characteristics
of product conforms to specified requirements, and all products carry traceable markings
that clearly define the build status information to which the product has been produced.
Confidential Page 8 14/06/2014

9. Annex A – Worked Example
Product Quality
Technical Report
Product:
AXH
Specialist: Mitchell, Darren
Synopsis:
Poor soldering of component
Opened: 14/12/2005
References:
(Bulletin, Ref No)
Product alert 101
"BonificaOscill261
2 sc15.doc"
Closed: 8/2/2006
Detailed
Description of
Issue:
Alert Number 101
Headline 151-2612/xx
Category Red
Type Quality
Issue/Problem Random failures (missing connections, switching off-
on, degraded performances, packet loss) during normal
Operation with loss of control towards the sub-rack units.
This is due to a bad soldering process with a poor solder
Reflow along the four pins of the THT component IC4907
Crystal Oscillator 19.44MHz (Marconi Code 68811-41/063)
Affected
Customer/s:
Primus, TransAct, BBCoE
Location: Dandenong 42, Primus network
approx 300, TransAct network
approximately 15
Affected
Inventory:
CA66AA and CA99A all cards
Location: Dandenong 42
History: See Reference
"MODIFIED
CA66AC6.xls"
16/12/05 42 Cards given to Startronics to re-solder.
22/12/05 Received 42 re-soldered cards back from Startronics.
19/1/06 Enrique sent 4 resoldered cards sent to Primus to replace lost / or stolen ones yellow spot applied.
Serial Nos: MA04IU0LT2, MA04IU0LRA, MA04IU02IF, MA04GU0CCS
23/1/06 One card found faulty (broken lever) Enrique put in RMA request, yellow spot applied.
Serial No: MA04FU068F
23/1/06 Remaining 37 resoldered cards sent to Hammond Rd store, yellow spot applied see picture.
6/3/2006 MA04JU0QC4 & MA05BU0HX6 belonging to Primus re worked in Startronics Dandenong.
ATT267619.jpg
Impact:
Confidential Page 9 14/06/2014

10. Cost of Poor
Product Quality:
(Include costs for
components,
manufacture
time, modifying
stock,
design,freight etc)
TIME TO FIX
10 minuets per card,
does not include
shipping
MATERIALS
Solder flux cleaner.
See quote from
Startronics
SUBCONTRACTOR
Startronics $12.50
per card see invoice
"RE Board
rework.msg"
"AXH solder
invoice.pdf"
OTHER Shipping.
To/from Syd $87.00 per
card as required. Not
required all cards in Mel.
Workaround:
(Including interim
work instructions)
As per BonificaOscill2612 (sc15). Doc
Action Plan:
(define solution,
outline resolution
recommendations
, minimise
COPPQ)
1. Book out from Stock 42 cards and inspect rework at Startronics Dandenong. Use ITR form
"ITR Form AXH
re solder.doc"
2. Inspect units in Sydney BBCoE and repair in house.
Actions Points: 1. Waiting on CSM for Primus/TransAct as to what if any action to be taken?
2. TBA possibly incorporates inspection as part of future upgrade. See CSM, R Grinham.
Confidential Page 10 14/06/2014