Joy Cooke Auditing Gage CSXT Dennis Devanney … Gage...CSXT Dennis Devanney Winchester Industries, Inc. Mark Lumadue Standard Steel, LLC 2:30 to 3:30 p.m. Auditing Gage Calibration

Transportation Technology Center, Inc., a subsidiary of the Association of American Railroads

27th Annual 2015 Quality Auditors and Industry Conference © TTCI/AAR, 1/10/2012. filename, p1

Joy Cooke

CSXT

Dennis Devanney

Winchester Industries,

Inc.

Mark Lumadue

Standard Steel, LLC

2:30 to 3:30 p.m.

Auditing Gage

Calibration

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AAR M-1003 QA Requirements for

AUDITING GAUGE CALIBRATION

The purpose of this presentation is to explain various techniques that can be used to audit an AAR M-1003 Gauge Calibration program in accordance with the requirements specified in AAR Manual of Standards and Recommended Practices, Section J, Issue of 2014, Paragraphs 2.8 through 2.8.10. AAR Auditor’s Conference

Jacksonville, FL 2015

AAR Auditor’s Conference Jacksonville, FL 2015

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BACKGROUND INFORMATION The AAR – Association of American Railroads – issues

the Manual of Standards and Recommended Practices. There are currently 28 manuals that specify requirements for design, fabrication, repair, reconditioning and maintenance of freight cars, locomotives, and their component parts.

Section J contains AAR Specification M-1003. It was originally adopted in 1985 as the Railroad Specification for Quality Assurance.

Freight car roller bearings and component parts were the original commodity governed by AAR M-1003.

Today there are more than 788 contractors manufacturing, assembling, or reconditioning more than 122 components governed by the AAR M-1003 Specification.


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AAR M-1003 Section 2.8.4 requires that calibration documents be maintained that include:

Equipment Type

Identification Number

Location

Frequency of Checks

Description of Check Method

Acceptance Criteria

Action to Take When Results Are Unsatisfactory


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Documented Procedures

EXAMPLE

OF A

METHOD OF CALIBRATION

OR

CHECK METHOD


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Procedure: Calibration of Height Gages Procedure No.: CP-2 Effective Date: 01/10/12 Page 1 of 2 Preparer Signature / Date: Jane Doe 1/2/12 Reviewer Signature / Date: John Smith 1/4/12 Revision: 3 1. Scope: 1.1 This procedure describes the method used to calibrate height gages. 2. Definitions: 2.1 None 3. Referenced Documents: 3.1 Form MT-1 Measuring and Testing Device Calibration Record 4. Responsibility: 4.1 It is the responsibility of the Quality Department personnel to follow this procedure when calibrating height gages. 5. Procedure: 5.1 Equipment 5.1.1 Master Gage Blocks 5.1.2 Length Standards 5.1.3 Surface Plate 5.2 Calibration frequency 5.2.1 Calibration shall be performed every six (6) months.


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Procedure: Calibration of Height Gages Procedure No.: CP-2 Effective Date: 01/10/12 Page 2 of 2 Preparer Signature / Date: Jane Doe 1/2/12 Reviewer Signature / Date: John Smith 1/4/12 Revision: 3 5.3 Calibration 5.3.1 Select three (3) gage blocks and/or length standards of various sizes within the range of the height gage. 5.3.2 Allow the height gage and the gage blocks and/or length standards to reach ambient temperature. 5.3.3 Visually inspect the height gage for damage or defects. 5.3.4 Run the gage head the entire length of the arm, moving back and forth, to check lead wear. Adjust as required. 5.3.5 Lightly oil all components. 5.3.6 Place gage blocks or standards on surface plate. 5.3.7 Measure the three (3) gage blocks and/or length standards using the height gage and record the results. 5.3.8 Check to required specification. Adjust if necessary. 5.4 Specification 5.4.1 The measured values shall not vary more than 0.001" from the certified values of the gage blocks and/or length standards. 6. Records: 6.1 The measurements of the three (3) gage blocks and/or length standards shall be recorded on form MT-1, titled "Measuring and Testing Device Calibration Record", the computer calibration system or both.


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Calibration Status AAR M-1003 Section 2.8.5 requires that

measuring and test equipment be identified with a tag, sticker, or other suitable indicator to show the calibration status.

The purpose of the status indicator is to provide a clearly visible indicator to the user that the gage is in calibration or alert the user that the gage is due for calibration.

The type of indicator to be used is dependent on the type of gage and the environment where the gage is used.

The contractor determines the type of status indicators to be used.


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Calibration Status

Calibration Stickers

Commonly used and include the following:

Calibration / Certification – as the header

ID No. – the serial number of the gage

By – the person who performed the calibration

Date – the date of the calibration

Due – the date for the next required calibration


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Calibration Status

Calibration Stickers – Alternate Methods

Apply Sticker to Gage Storage Container – many small micrometers, dial indicators, calipers, etc. are stored in a box or container. Some facilities use gage storage boards. It is normally acceptable to apply the calibration sticker to the container. If several gages are stored on the same board, a sticker unique to each gage should be posted. It is important that each gage be permanently marked or etched with a unique serial number.


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Calibration Status Calibration Stickers – Alternate Methods

Color Coding – Gages can be color coded to indicate calibration status. The gage is painted or marked with a unique color. A calibration status instruction or board must be posted in the work area and must be readily accessible by the gage user.

Caution: - Calibration records are critical. With no date on the gage, the calibration record is the only objective evidence when the gage was calibrated.

Serial Number must be etched on the gage.


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Calibration Status

Calibration Stickers – Alternate Methods

Engraving / Stamping – Gages subjected to harsh environments that destroys stickers or paint codes can be engraved or stamped with a unique serial number and the calibration date.

Instructions or procedure for determining calibration due date must be posted or readily available for the gage user.


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Records Retention AAR M-1003 Section 2.8.6 requires that

calibration records be maintained for measuring and test equipment.

Contractor determines type of records – paper or computer – must at a minimum include all specified in M-1003 section 2.8.4.

Must ensure documented traceability to nationally recognized standards.

The majority of standards can be traced to NIST – National Institute of Standards and Technology.


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Records Retention

TYPICAL NIST REFERENCE NUMBER

821 / 252343 – 14

Internal Year Lab # 6 Position of Test Traceability # (first character may be "alpha")


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Simplified Traceability Flowchart

Nationally Recognized Standard

Master Gage Calibration Record

Gage Calibration Record

Gage


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Auditing Techniques

A typical audit of a calibration system usually starts with a thorough review of the QA Manual and any supporting procedures and related documents.

The auditor will interview personnel responsible for the calibration process.

A random sample of gages or test devices will be taken. Size of sample will vary based on total number of gages in your system.

The auditor may ask for a master list of gauges. The auditor could select specific gauges, making note of the serial number and location, and then proceed to the work area to determine if the gauge is in the proper location as indicated on the calibration records.


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WHEEL, WHEEL BEARING, SIDE FRAME & SIDE FRAME PARTS GAUGES

PG # GAGE I.D. CAL. DUE GANG GAGE LOC. STATUS DESCRIPTION

MODEL #

7 022496-2 SENT BACK TO BACK MOUNTING GAGE N/A

8 100900-1 9/2/2015 TRUCK TRACK

1/2 BACK TO BACK MOUNTING GAGE N/A

9 072096-4 STORAG

E SIMPLIFIED WHEEL GAGE RP-615-77

12 112200-37 3/11/2015 TRUCK TRACK

2 SIMPLIFIED WHEEL GAGE RP-615-77

Master List of Project Shop Gages REVISED 9/3/2014


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Auditing Techniques

After review of the calibration procedures, the auditor will proceed to the shop to determine if the procedures have been implemented.

A random sample of gages or test devices will be taken from the production areas. Size of sample will vary based on total number of gages in your system.

The auditor will interview personnel using the M&T devices to determine understanding of the use of the device, calibration stickers, etc.

The auditor will make note of gauge ID number, calibration dates, location, etc.


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Typical Audit of Traceability

The auditor will ask to review the calibration records for the specific gauges sampled during the tour of the facility.

Records must be readily available, and may be on-line, or hard copy.

We will now audit a typical gage to ensure the proper documentation exists to provide traceability to nationally recognized standards.


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Typical Audit of Traceability

The auditor will make note of the gage description, serial (ID) number, workstation, and calibration dates. You will be required to show the documented record trail from the gage to nationally recognized standards as follows:

T101 1-8987 COLUMN LAND SURFACE GAUGE

ASF 125 TON WIDE LAND GR. C RIDE CONTROL

Engraved

CALIBRATION ID No:____T 101________ By: _MAL_ Date:_8-1-14_ Due: __8-1-15__________


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Form: MT-1 Rev. 1, 01/02/13 ___________(Your Company Name)__________

MEASURING AND TESTING DEVICE CALIBRATION RECORD ASF 125 Ton Wide Land GAUGE ID NUMBER: __T 101_____ DESCRIPTION: _Column Land Surface____ WORKSTATION: Pos. #3 TOLERANCE: + / - .020" MASTER: ____V 002_____________ CALIBRATION FREQUENCY: _ANNUAL___ PROCEDURE: CP – 201

DATE

ACCEPT/ REJECT

PERSON CHECKING

REMARKS

8 – 1 – 14 ACC MAL

The auditor will review the record for the working gauge ID # T 101 to ensure the information on the gauge and calibration sticker match. The auditor will then make note of the master gauge used to check the working gauge to continue the audit of the traceability to nationally recognized standards. You will now be requested to show the auditor the record for master gauge ID # V 002, as follows:

CALIBRATION ID No: T 101 By: MAL Date: 8-1-14 Due: 8-1-15

Note: Information on sticker must match the calibration record.


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MEASURING AND TESTING DEVICE CALIBRATION RECORD GAUGE ID NUMBER: __V 002_____ DESCRIPTION: 24" Vernier Caliper ___ WORKSTATION: Gauge Room TOLERANCE: + / - .0005" MASTER: Gauge Room Set – GB1_ CALIBRATION FREQUENCY: _6 Month ___ PROCEDURE: CP – 101

DATE

ACCEPT/ REJECT

PERSON CHECKING

REMARKS

1– 23 – 14 ACC MAL

Used Blocks

2, 4, 6, 12"

7– 23 – 14 ACC MAL Used Blocks

2, 4, 6, 12"

The auditor will review the record for the master gauge ID # V 002 to ensure the information on the gauge and calibration sticker match. The auditor will make note of the master gauge used to check gauge ID # V 002 to continue the audit of the traceability to nationally recognized standards. The record for master gauge block set ID # GB1, follows:

Note: Record the actual gauge blocks used from a set of blocks. When the set ID, such as "GB1" is etched on the individual blocks, it is normally acceptable to record only the size of block used. You will need to record the ID number for each block when the set ID is not on the individual blocks, or when a block within a set has been replaced.


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MEASURING AND TESTING DEVICE CALIBRATION RECORD GAUGE ID NUMBER: __GB1 _____ DESCRIPTION: Gauge Block Set ___ WORKSTATION: Gauge Room TOLERANCE: Grade 2 MASTER: NIST No: 123/123456-14_ CALIBRATION FREQUENCY: _3 Year ___ PROCEDURE: TTCI CP – 10

DATE

ACCEPT/ REJECT

PERSON CHECKING

REMARKS

1 – 15 – 14 ACC

TTCI Gauge

Company

The auditor will review the record for the master gauge block set ID # GB1 to ensure the information on the gauge block set and calibration sticker match. It is very important that your calibration record specifies the calibration frequency for any gauge sent out to a subcontractor for calibration. The subcontractor may print their recommended interval on the certificate of calibration, and it may not agree with your specified calibration frequency. The auditor will verify that the certificate of calibration describes the check method, lists the gauge block ID numbers or set number, tolerance, nominal size and deviation for each block. The certificate must include the NIST test number, or the subcontractor must meet the requirements of AAR M-1003 sections 2.9.1.2 and 2.9.1.3, i.e. accredited by a recognized third party to perform calibration. The certificate must show the name of the subcontractor and be signed and dated, as follows:


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Certificate of Calibration TTCI GAUGE COMPANY

100 Main Street, Pueblo, CO

Calibration Date: 1-15-14

Style: ENGLISH, RECTANGULAR, STEEL, GRADE 2 Mfg. Serial No. 1001, Owner Serial No. "None", Etch GB1 Sold to: (Your Company Name and Address) P.O. No. 23756

***DEVIATION (ERROR) EXPRESSED IN MICROINCHES***

Nominal Size Error

.250 0

.500 -1

1.500 +2

2.000 0

4.000 +1

6.000 +1

12.000 -2

16.000 +1

Calibration performed in accordance with ISO/IEC 17025 and TTCI Procedure CP10.

We certify that these gauge blocks were checked using masters traceable to the National

Institute of Standards and Technology on January 4, 2014, test number 123/123456-14.

These are new gauges. Your recommended recalibration date is January 15, 2015.

Calibration standards used:

Master Gauge Set: MG1 calibrated 1-4-14, due 1-4-15.

Electronic Gauge Block Comparator: BC1 calibrated daily.

Calibrated by: John C. Doe

Approved by: Mary S. Jones

OK

1/19/14

MAL

Important to include the ID number, and the NIST Traceability number.

Note review date and initials.


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TRACEABILITY AT WINCHESTER INDUSTRIES

N.I.S.T. LS STARRETT CO.

ATHOL, MA

METROLOGY

LABORATORY

WINCHESTER INDUSTRIES, INC

MASTER BLOCK SET

WINCHESTER INDUSTRIES, INC

WORKING BLOCK SET

CMM

MASTER GAUGE FOR OPTICAL COMPARATOR

OPTICAL COMPARATOR

W785A MASTER GAUGE

STEEL WHEEL GAUGES

SUPER MICROMETER

DIAL INDICATOR

MICROMETER

HEIGHT GAUGE


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Method of Verification

A verification procedure is required and must specify the verification process for a specific method. Appropriate methods include:

Certified Metrology Lab Verification Contour Mapping Master Gauges Go – No Go Gauges Toleranced Dimension Verification Measurements using Certified Test Equipment


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Reference Authority

The recognized organization responsible for issuing and maintaining the specification used to verify the measuring and test equipment. Example include:

Manufacturers of M & T equipment (OEM) Government Agencies Trade Organizations ANSI


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Reference Specification

The detailed definition used as the basis for verification. Usually dependent on a reference authority. Example include:

Product Specifications Manufacturers drawings Trade Standards ANSI Specifications Quality Program Specifications Winchester Industries, Inc. drawings


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Non-Conforming Gauges

Measuring and Test Equipment is designed to properly verify product throughout it’s entire life cycle.

It is normal to expect M & T Equipment to eventually fail at time of re-certification.

NORMAL FAILURE occurs when equipment “eases” out of the tolerance range due to normal use. Equipment is typically designed to reach this condition without affecting the product verification process.

GROSS FAILURE occurs when a device fails prematurely and affects product quality. An ASSESSMENT of affected product must be performed.


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Interpretations

Any calibration device used to measure product “quality” would fall within the scope of M & T criteria. (Newsletter 01/04/94)

In general, “reference” gauges do not require calibration. This depends on the application of the gauge. (Newsletter 10/24/97)

Are weld fillet gauges required to be calibrated? When used as “reference” – No.

Are tape measures required to be calibrated? When used as “reference” – No.

If either of these gauges is used to “measure product quality” – they must be calibrated.


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Questions ?

AAR M-1003 QA Requirements for

AUDITING GAUGE CALIBRATION