Congratulations to all!  ISO 9002 Audits Successfully completed!!!!

MOUNTAIN VIEW

Mountain View received NO action requests on the latest ISO 9002 surveillance audit May 1^st.  One “Observation” was reported.  See Summary below.

LAKE FOREST

Lake Forest successfully completed the last ISO 9002 audit March 21^st, with only one action request, and 2 Observations.  See Summary below.

LONDONDERRY

Londonderry completed their first audit in the new building November 8, 2001.  A summary was sent previously.  Additional copy available upon request.

Every audit requires team participation to be successful.  Thanks to everyone for making sure operators are trained, procedures are up to date and followed, facilities are clean.  The audits are a chance to stop and look at whether we are doing what we say we should do to ensure we meet our goals of Customer Satisfaction.  It’s a sample of what happens every day.  We always have room for improvement.  Some of these opportunities are found through the UL ISO 9002 audits, and some in our own evaluations or Customer feedback.  Everyone is invited to make suggestions for improvement, and to report nonconformance by requesting corrective action.  Our commitment is to use this input for continuous improvement.  Please feel free to email, or use the Corrective Action Request form found on the Prowler.  Everyone’s participation makes a difference.

MOUNTAIN VIEW AUDIT SUMMARY

1. OPENING/CLOSING MEETINGS:
   Geert Breesch, Mike Boardman, Mike Plouffe and Shari Frank all attended the Opening or Closing Meetings (or both).
   
   
2. OPEN ACTION REQUESTS FROM MARCH 2001 AUDIT:
   Both of the two action requests from previous audits were reviewed and closed.
   • Prepreg storage area was reported as not being controlled.  Records were provided that showed the area has been maintained within specification for more than the past year.  Records show repairs have been made as needed, and the controls were in spec at the time of the audit.  Thanks to Mike Boardman for maintaining the temperature & humidity charts, and to Geert Breesch for providing repair info.  Action Request successfully closed.
     
   • Preventive maintenance records of all equipment were not available for review.  Arlan Barrientos, went to great lengths to take information out of the antiquated MaintainIt software system, and create master preventive maintenance schedules for each machine.  He borrowed several of Lake Forest’s check lists created by Carlos Garcia.  He showed completed records for the past few months!  This provided the evidence needed to show a P.M. system exists, and close the Action Request.

3. PROCESS CONTROL and CONTROL OF NONCONFORMING PRODUCT:
   Daniel Ayap and Dave Martinez showed the auditor how they check product size and hole quality in the prepreg cutting, tooling and packaging department, explaining all the Quality Steps on the M.O.  Regarding non-conforming product, Mike Boardman and Mike Plouffe showed recent examples of a non-conforming roll reported to Isola complete with CATS form and digital pictures of the defects.  Geert Breesch showed how a Customer Corrective Action is processed, and said that he may request an internal corrective action if warranted, even if not requested by the Customer. 

4. CALIBRATION:
   Mike Boardman’s up to date list of calibration certificates and items showed the system is working.  We came away with a suggestion for improvement where Insulectro will specify to the Calibration houses use of NIST standards for tolerances, getting away from manufacturer’s tolerances.  This will help us improve control over the calibration services. 

LAKE FOREST AUDIT SUMMARY

1. OPENING/CLOSING MEETINGS:
   Dan Morales, Linda Brigham, Dan Diesel, Ann Williams, David Klebba, Tim Redfern, David Beaver, Luis Hernandez and Shari Frank all attended the Opening or Closing Meetings (or both).  ISO 9002 revision 2000 is coming soon.  One of the big changes will be a requirement for executive management to participate in the ISO audit process.  With this turn-out, it showed we’re on the right path.  ISO 9002 upgrades to the 2000 revision must be completed by May 2003 for UL.

2. PROCESS CONTROL, INSPECTION AND TEST:
   Rafael Martinez and Saul Martinez were a little nervous but they did a great job showing the auditor how they keep the panel process in control.  These guys whisked though their checks, clearly showing they do this stuff every day.  Using the hand held caliper, they read the material thickness, then compared it to the M.O. to be sure it is in spec.  They then picked up the coppertron and checked copper thickness both sides, and wrote down the results on the M.O. Using the tape measure, they verified the diagonal sheet size to make sure the sheets were square, checked the length and width of each of the cut panel stacks, showed how they determine stack height, saw speed, and use entry material.  Last but not least, they walked thru use of the blade log to track inches and when to send the blade out for cleaning, and resharp.
   • One error found on an M.O. resulted in an “Observation” by the auditor.  The Stiffener quantity was incorrect, showing 20 instead of 25.  The operators failed to take action to get the M.O. corrected.  Lesson to be learned here:  make sure errors get reported and changed on the M.O.  After looking at about 30 more M.O.s, no other errors were found.
     
     
3. CONTROL OF NONCONFORMING MATERIAL:
   In the warehouse, David Klebba walked through the rejection process, including rejecting the material in the ePredator, re-labeling it so it has trace ability to the system information showing why material was rejected and what the status is.  The MRB area is segregated for all the items without special environmental requirements.  In prepreg, even though packages were clearly labeled as rejected, they were not in a segregated area, so we received an Action Request to fix that.

4. MANAGEMENT RESPONSIBILITY, CORRECTIVE and PREVENTIVE ACTION, INTERNAL AUDITS: 
   Every audit looks at Management Review meeting minutes, Corrective Actions (Customer, Supplier and Internal), Preventive Action, and Internal Audits.  Lake Forest is working on two Preventive Actions:  Improving Blade Quality and Improving Drill Quality.  Two new blades are being evaluated and if approved, will be recommended for purchase at Mountain View and Londonderry when new blades are needed.  With drilling, different bits are used at Lake Forest and Londonderry.  We plan to review Unichem drill bits to see if they get the longer life, better hole quality marketed.
   • Checking out internal audits, the auditor said we need to specify in the procedure when a corrective action will be issued to correct nonconformance found in audits.  If failure to fix an issue causes risk to product or Quality System integrity, this will be cause for a corrective action going forward.  This is the 2^nd “Observation” for the Lake Forest audit. 

*** COMING SOON ***

LONDONDERRY and LAKE FOREST audits will be August/September.

Since we are registered as a corporate account, Lake Forest is audited every 6 months, Londonderry and Mountain View alternate each 6 months.

If you would like any further information, please feel free to call Shari Frank at (949) 587-3371