Quality Managment Menu
“Stainless Foundry & Engineering’s Quality Management department is prepared to meet the growing needs of the evolving quality/material standards, inspection needs, and demanding technical challenges not just in metallurgical issues but also in the QA arena. Our prevention and inspection practices are set to be mutually beneficial to all involved whether it be customer, vendor, and the Foundry. We are here for you whenever you need us.”Quality Management Overview
The Quality Policy Manual describes the following quality systems SF&E is certified in: ISO 9001:2008 Edition, European Directive 97/23/EC for Pressure Equipment (PED), & DNV approval of manufacturing of Steel and Non-Ferrous – standards for certification number 2.9 approval of manufacturers number 303.
The Quality Policy Manual describes the following quality systems we are in compliance with: ASME B & PV Code Section III NCA-3800; 10CFR50, Appendix B; MIL-I-45208; MIL-Q-9858; and Norsok M-650.
Stainless Foundry & Engineering, Inc. works our quality system to maintain compliance to the above aforementioned quality system compliance section. We currently have a Quality Policy Manual , Quality Management Procedures (QMP’s), Safety Management Procedures (SMP’s), and over 500 Work Instructions (WI). All procedures are maintained by QM in a controlled format.
Currently the QM/QA/QC department is staffed by the following personnel:
- QM Director
- QM Inspection Supervisor
- QM Engineers - Dimensional Layout Specialists (2)
- QM Contract Specialists (2)
- Welding Program Coordinator
- QM Final Inspectors (2)
The QM Director administers and implements the quality system by:
- identifying quality problems;
- initiating, recommending, or providing solutions to quality problems through designated channels;
- verifying implementation of solutions; and
- assuring that further processing, delivery, installation, or use is controlled until proper disposition of a nonconformance, deficiency, or unsatisfactory condition has occurred.
Special Processes Employed
SF&E personnel perform NDE (liquid penetrant, visual inspection), welding, and heat treatment.
Radiographic, ultrasonic, and magnetic particle inspection is subcontracted to qualified and approved sources. All NDE personnel are qualified and certified to the requirements of SNT-TC-1A and Mil-STD-410.
Welding procedure specifications and welders are qualified and certified to the guidelines set forth in ASTM A488, ASME Section IX, MIL-STD-248, and S9074-AQ-GIB-010/248. In some instances, we have also qualified welding procedure specifications to the European requirements of EN-288.
The heat treating performed in-house is primarily for the investment Foundry. Approved vendors perform heat treating of sand Foundry castings.
Verification
Travelers follow a job physically through the Foundry, as well as via the AS/400 shop order system when special instructions are necessitated by a customer or internal requirements. Travelers help the Foundry produce castings that consistently meet the specified requirements. Traceability is maintained by stamping the heat number on the casting. Chemical, physical, and metallographic analysis capability resides in-house. Our technical service personnel include metallurgists and technicians.
Final inspection, either 100% or sampled per the requirements of ANSI Z1.4 or Mil-STD-105E, is performed on the castings prior to release for shipment. We conduct dimensional inspection of castings, dies and patterns on coordinate measuring machines in the investment Foundry and the machine shop, as well as on a Portage layout machine in the sand Foundry. Samples are dimensionally inspected to ensure compliance with the drawing requirements. Depending on the design complexity and the Alloy, the casting may be inspected by radiography and/or liquid penetrant.
Continuous Quality Improvement
Continuous quality improvement is forwarded by the efforts of our Material Review Board (MRB) in conjunction with a quality improvement/training manager and is facilitated by regular courses conducted in a well-equipped training center. Classes focus on standardization of our foundry practices, such as core making, molding, pouring, etc., as well as on the use of statistical process control (SPC). The essential elements of Lean & Six Sigma are followed and personnel are trained to Lean & Six Sigma from the top down to most levels of the organization.
Stainless Foundry & Engineering, Inc. is committed to continuous quality improvement and providing our customers with castings, meeting the required specifications and the requested delivery date.