Mercer Forge Corporation

Mercer Forge Corporation's Quality Control Department

Quality Policy:

Mercer Forge Corporation Recognizes the Importance of Consistency of Processing in Manufacturing it's Products, with the Intent of Continuous Improvement of Quality and Customer Satisfaction.

Objectives:

Meet All Defined Customer Requirements in a Cost Effective Manner Reflecting Continuous Performance Improvement
Decrease Customer Concerns
Increase Customer Satisfaction as Measured by Objective "Customer Satisfaction Survey" Scores
100% On-Time Shipments to Customer Schedules
Decrease Scrap and Re-Work
On-Time Completion of "Product Part Approval" with Decreases in Average Production Development Lead Times

APPLICATION OF S.P.C. CHARTS

Control Items	Method	Sample Frequency	Definition	Corrective Action
Shear Weight	X-R Chart	3pieces Per 2hours	Weight of Cut Billet	Stop Adjustment
Thickness	X-R Chart	3pieces Per 1hour	Overall Height of Forging	Die Adjustment
Mismatch	X-R Chart	3pieces Per 1hour	Alignment of Top and Bottom Dies	Die Adjustment
Microalloy	Brinell Hardness Tester	36 - 60pieces Per 1hour	As Forged Hardness After Special Cooling Techniques	Cooling Rate Adjustment

Mercer Forge Corporation Depends Primarily on Statistical Process Control to Insure Uniform, Traceable, and Aesthetic Products that Meet Customer's Needs. The System Provides Assurance that Normal Blueprint and Forging Standards (Guideline Tolerances by FIA) are Exceeded. Equipment and Systems are Controlled by Persons Specifically Trained in S.P.C. and Related Areas. Major Customers Play Key Roles in Helping to Develop Systems Representing a Wide Cross Section of Quality Assurance (QA) Projects: Including "TARGET FOR SUCCESS."

Mercer Forge Corporation Personnel will Assist Customers in:

Setting Target Cp/Cpk Indices
Critical Dimensional Characteristics
Failure Mode Analysis Studies
Capability Studies
Sub-Supplier Audits
Overall Goals of QA for Any Given Part

Mercer Forge Corporation Production Personnel also Receive Formal Training in All Facets of QA. Specific Persons have been Designated to be Responsible for Practical as well as Statistical Data Processing. Toward that Goal, Computers/PCs are Used for Data Storage and Interpolation of Various S.P.C. Charts. CMM's (Coordinate Measuring Machines) are Utilized for PPAP Data as well as First and Last Piece Inspection Studies.

Mercer Forge Corporation's "Quality Rated Badge" is Worn by Crew Members that Have Demonstrated, by Actions and Written Testing, that the Crew Itself Acts as the Quality Inspector for Any Given Job. The "Hot Inspector" (Utilized in Most Forge Plants) is Not Needed at Mercer Forge Corporation. The Forging Crew Measures the Parts Produced and Creates the "TARGET FOR SUCCESS" within MINUTES after Forging. Corrections (If Needed) are Implemented IMMEDIATELY and Not Hours Later.