Compliance Assurance Program, In-Plant Quality Assurance Manual [KEN TO CONFIRM: legal entity name] | MT-QAM Rev. 0 (draft, not submitted)

This appendix answers ICC/MBI 1205 §501.17‡, which requires the forms used as part of the program to appear in the manual together with a written procedure for how each form is used, and Montana bureau list item MT-6, sample of inspection control form used. It also answers the Montana list item MT-7, record-keeping procedures for quality control forms, in combination with §14 of the manual.

The ‡ mark carries the same meaning as in the manual: the ICC/MBI section number came from the posted approved ballot draft of the standard and must be verified against the purchased 2021 edition before submission. [KEN TO CONFIRM: ...] marks a fact about the plant that does not exist yet. [PE TO SET: ...] marks a numeric criterion the engineer of record must set.

A.0 Rules that apply to every form#

1. Every form carries a footer reading QF-nn Rev. __ | MT-QAM Rev. __ | page __ of __. Forms are controlled documents registered on QF-29. A superseded blank is withdrawn from the floor when a revision is issued.
2. Entries are made in ink at the time the work is done, by the person who did it. No form is completed in advance and no form is reconstructed afterwards.
3. A correction is a single line through the error, with the correct value written beside it, initialled and dated. Entries are not erased, whited out or overwritten.
4. A blank field is not an accepted field. Where a characteristic does not apply, N/A is written and initialled. Where an inspection was not performed, the item does not advance.
5. A signature is a signature, written by the person's own hand, with the date. Initials are acceptable only where the form's signature block also carries that person's full signature and printed name once.
6. Every form that concerns a specific product carries the serial number assigned under manual §10.1, so that the record can be found from the product and the product from the record.
7. Where a form records a measured characteristic against a criterion, the measured value is written, not a tick. A tick records that somebody looked; a value records what they found.
8. Filing, access and retention are per manual §14.

A note on media. [KEN TO CONFIRM: whether these forms are run on paper, in a spreadsheet, or in a production system. This appendix is written as paper forms because a paper form can be signed at the bed and because ICC/MBI 1200 §503.2‡ requires a printed copy of the approved plan in the plant. If any form is run electronically, the manual must state how the electronic record is protected from alteration, how a signature is attributed to a person, and how a record is produced to an inspector who arrives without notice.]

PART 1. MATERIALS AND PURCHASING#

QF-01 Approved vendor and testing agency list#

Form layout

Header: Issue no. ____ Issue date ____ Supersedes issue ____ Approved by ____

[KEN TO CONFIRM: every row. No vendor has been approved and no laboratory has been selected.]

Procedure of use

1. A vendor is added only by the quality manager, and only after form QF-02 records the evidence of approval.
2. Purchasing issues an order for a quality-affecting material only to a vendor shown Active on the current issue of this list.
3. Receiving checks the vendor on this list at every delivery and rejects a delivery from a vendor not on it, under manual §5.6.
4. A vendor whose material has caused a nonconformance is either moved to Suspended, which blocks new orders, or is left Active with increased receiving inspection recorded on QF-02.
5. The quality manager reviews the whole list at least annually and at each management review, and reissues it with a new issue number whenever any row changes.
6. A change of cement source or of foaming agent supplier on this list triggers mix requalification under manual §6.3 before the material is used.

QF-02 Vendor evaluation record#

Form layout

Procedure of use

1. Open a sheet before a vendor is added to QF-01, and record the evidence relied on.
2. Record every delivery event that matters: a late delivery that forced a substitution request, a missing or wrong certification, a receiving rejection, a nonconformance traced to the vendor's material.
3. Cross-reference every nonconformance report number so that the vendor's record and the product's record point at each other.
4. Review annually, record the decision, and update QF-01 to match.

QF-03 Incoming material receiving and inspection log#

Form layout

Header: Page ____ Month ____ Plant ____

Standing check list printed on the reverse of the form, taken from manual §5.3:

Procedure of use

1. Every delivery goes to the quarantine area and is entered on this log on the day it arrives. Nothing goes to stock before the inspection line is signed.
2. The receiver enters the delivery data and the certification received. The QC inspector performs the checks on the reverse, writes what was checked, and signs accept or reject.
3. On accept, the material is moved to stock, the release column is initialled and dated, and the certification is filed and indexed on QF-04.
4. On reject, the material is red-tagged and moved to the rejected material area, the quality manager countersigns, and QF-05 is opened.
5. Where the certification has not arrived with the delivery, the material stays in quarantine. It is not released to stock against a promise of a certificate.
6. Where a material with a shelf life is accepted, the lot is also entered on QF-06 the same day.

QF-04 Material certification file index#

Form layout

Procedure of use

1. Index every certificate on the day it is filed.
2. Add the production order to the "orders used on" column each time the lot is drawn for an order, so that a recall or an investigation can go from a certificate to every panel it touched.
3. Screw and insert evaluation reports, and appliance listings, are indexed once and carried forward; the index row records the revision or issue date of the report so that a superseded report is detectable.
4. The index is checked at every internal audit by selecting a released serial number and tracing it back to every certificate.

QF-05 Rejected material tag and disposition log#

Tag layout (red card, wired to the material)

REJECTED  -  DO NOT USE  -  DO NOT RETURN TO STOCK
Tag no. ______   Date ______
Material ______________________  Lot / heat ______________
Quantity ______________  QF-03 line ref. ______
Reason __________________________________________
Rejected by ______________  Location: rejected material area
Removal from this area requires the quality manager's signature on QF-05.

Log layout

Procedure of use

1. Tag the material at the moment of rejection, before it is moved.
2. Move it to the segregated rejected material area. Where it is too large to move, barricade and tag it in place and record the location on the log.
3. Enter the tag on the log the same day.
4. Material leaves the rejected area only on a signed disposition line. A verbal release is not a release.
5. Where rejected material had already been placed in product, open a nonconformance report QF-22 against that product and enter its number on this log.
6. Where the rejection reflects on a vendor, update QF-02.

QF-06 Shelf life and stock rotation log#

Form layout

Header table, filled once from the manufacturers' data:

Body:

Monthly review block: Reviewed by ____ Date ____ Items within 30 days of expiry: ____ Action: ____

Procedure of use

1. Enter every shelf-life material on this log the day it is received, at the same time as the QF-03 entry.
2. Mark the container with the use-by date in a way that is readable at the mixer.
3. Draw stock oldest first. Record the date a container is first drawn.
4. The batch operator checks the use-by date at the mixer before charging foam concentrate or admixture, and writes the container batch number on the batch log QF-09.
5. The quality manager reviews this log monthly, quarantines anything expired under manual §5.6, and lists anything within 30 days of expiry so production can plan around it.

PART 2. CONCRETE#

QF-07 Mix design record#

Form layout

Procedure of use

1. A mix is not used in production until this record is complete, the qualification on QF-08 is attached and both signatures are present.
2. The batch operator batches only to the current revision at the batch station. The operator has no authority to adjust proportions, and water is not added to improve workability.
3. Any change to any row is a new revision, requires requalification under manual §6.3 where the change is one of the triggers listed there, and goes through document control on QF-29.
4. The record is reissued to the batch station and the superseded copy withdrawn on the same day.

QF-08 Mix qualification and requalification record#

Form layout

Conclusion block: Mix qualified for production: Yes / No. Quality manager ____ date ____ Engineer of record ____ date ____ Laboratory reports attached: list ____

Procedure of use

1. Open a record before the mix is first used, and again on every trigger listed in manual §6.3.
2. Run the qualification with the plant's own equipment, methods and curing environment, not with laboratory convenience batching. A qualification run under conditions the plant does not use proves nothing about the plant.
3. Attach every laboratory report. A result quoted without its report is not evidence.
4. Do not release the mix to production until the conclusion block is signed.
5. On a requalification, state plainly what changed and compare the new results to the previous qualification on the same form.

QF-09 Daily batch and density log#

Form layout

Header: Date ____ Shift ____ Ambient temp. start ____ F Weather ____ Mix ____ Rev ____

Pre-run batching device check, manual §6.4 item 2:

Batch body:

Density and temperature body, at the point of placement:

Out-of-band block:

Footer: Batch operator ____ QC technician ____ Quality manager review ____ date ____

Procedure of use

1. Complete the pre-run device check before the first batch of each production run. A device that fails is tagged out of service and no batching occurs on it.
2. Record every batch as it is made. The batch number is assigned sequentially within the day and is the link between the concrete and the panel: it is written on the traveler QF-13 of every panel the batch reaches.
3. Take a fresh density reading at the point of placement on the first placement of each batch and at intervals not exceeding 30 minutes while placing continues, following ACI 523.1R-06 §4.3 and §5.3. Record the reading, not a tick.
4. Record the concrete temperature and the ambient temperature at the same times, and record the weather whenever it is near the cold or hot weather limits at manual §6.9.
5. A reading outside the acceptance band stops placement. Complete the out-of-band block, check the batching devices, identify every panel the batch reached by serial number, and raise a nonconformance under manual §6.10 and §9.
6. Cast cylinders at the frequency the mix design and manual §6.6 require, at the same time as a density test, and cross-reference the QF-10 set number here.
7. The quality manager reviews and signs the log daily and files it with the order.

QF-10 Cylinder cast and break log#

Form layout

Results:

Procedure of use

1. Cast specimens at the same time as a density test, at the point of placement, and by the filling and consolidation method stated on the mix design, so that the specimen represents the product. This is not a formality with foam concrete: a specimen consolidated differently from the panel does not represent the panel.
2. Mark each cylinder with the set number, the date and the mix before the concrete sets.
3. Record the fresh density of the concrete the specimens were taken from, on this form as well as on QF-09, so that a low break can be read against the density it came from.
4. Cover and store the specimens in a protected area for at least 24 hours before transport, per ACI 523.1R-06 §4.3.
5. Record the transport and the laboratory. Attach every laboratory report to this log.
6. Enter each result on the day it is received. A 7 day result below expectation is acted on immediately and is not left to be confirmed at 28 days.
7. A result below the design strength is a nonconformance against every panel the batch was placed in, identified from QF-09, and is handled under manual §6.10.
8. Overdue results are reviewed at each internal audit. A pending 28 day result on released product must be traceable to the engineer of record's written acceptance of early release recorded on QF-20.

QF-11 Cure log#

Form layout

Header: Bed ____ Cycle no. ____ Pour date ____ Pour complete time ____ Mix ____ Curing method ____ Concrete temperature at placement ____ F Ambient temperature at placement ____ F (both from QF-09)

Accepted cure temperature range in force for this log (manual §6.8 item 3). Write it here before the first daily reading is taken, so that every reading on this sheet is read against it:

Release block:

Procedure of use

1. Open a cure log for every bed cycle at the moment the pour is complete, and fill in the accepted range block in the header before the first daily reading is taken, by copying it from the current revision of QF-07 for the mix. If QF-07 does not yet carry a range, write NOT SET, §6.8 there. A log whose header is blank cannot say whether a reading passed or failed.
2. Record the temperature at the bed at least once each day, from a calibrated instrument on the calibration register, with the time and who read it. Carry the concrete and ambient temperatures at placement across from QF-09 into the header. Write the value, never a tick, including on the day it is in range.
3. No panel is stripped until the release block is signed. Stripping without that signature is a nonconformance against the panel.
4. Where a range is in force and a day's temperature falls outside it, write the value, mark the "in range" column N, notify the quality manager the same day, and hold the panels pending the disposition at manual §9. Do not sign the release.
5. Where no range is in force, which is the position today, mark the "in range" column range not set, still write every value, and mark the release line range not set rather than Yes. A reading below 32 F or above 100 F is referred to the quality manager before the release is signed and the outcome is written in the release block. That referral is a trigger, not an acceptance criterion: it does not make the readings between those two numbers acceptable, and nobody may treat 32 F to 100 F as the range. The release is made on the seven day elapsed rule alone until the engineer of record sets a range on QF-07.
6. File the cure log with the production order and cross-reference it from each panel's traveler.

PART 3. PRODUCTION#

QF-12 Daily production log#

Form layout

Header: Date ____ Shift ____ Crew present ____ Weather ____

Problems and deficiencies found today:

Downtime, equipment and visitors:

Footer: Production lead ____ Quality manager review ____ date ____

Procedure of use

1. One log per production day, opened at the start of the shift.
2. The "problems and deficiencies" block is completed even when the problem was fixed on the spot. A problem that is only fixed and never recorded is a problem that will recur and that no audit can see.
3. Record every visit by the third-party inspection agency or the bureau, with the report number if one is issued.
4. The quality manager reviews and signs each day's log and follows up any entry that should have produced a nonconformance report but did not.

QF-13 Panel and unit traveler, in-process station sign-off sheet#

Form layout

Header block:

Station lines:

Nonconformance block:

Label block:

Site record block, for a panel erected on a site (manual §13.7). Completed after release, from the record the erector returns. It is not a station line and it is not signed by a station signer:

Procedure of use

1. The quality manager opens a traveler for every item when the order is released, with the serial number already assigned from QF-28.
2. The traveler stays with the item, or at the item's station in a controlled holder. It is not kept in the office.
3. Each station's signer signs their own line, by their own hand, after the work and the inspection are done. Signing another person's line, or signing in advance, is falsification of a quality record.
4. At a HOLD line the item does not advance until that line is signed. Any person may stop an item; only the named signer may release it. There are six HOLD lines: lifting inserts (line 3, items with cast-in inserts), pre-pour (4), cure (6), the wall panel pick before the first lift (7), the MEP rough-in before the cavity fill (11), and final release (15).
5. Lines 3 and 7 are the two halves of the lifting form QF-16 and are mutually exclusive: an item with cast-in inserts signs line 3 and marks line 7 N/A; a wall panel signs line 7 and marks line 3 N/A. Neither line is left blank.
6. Line 12 comes before line 13 and the order is not interchangeable. The cladding is one of the two faces that contain the fill. A unit whose fill was pumped before the cladding went on was pumped into an open cavity, and the concrete cannot be taken back out.
7. Where a nonconformance is raised, enter it in the nonconformance block, and record the disposition and the re-inspection when they happen. The traveler carries the item's whole history, including its failures.
8. The quality manager closes the traveler at release, records the labels applied, and files it with the order.
9. A traveler with an unsigned line cannot be closed and the item cannot be released.
10. The site record block is filled in after the traveler is closed and does not reopen it. It is the cross-reference from the panel to the erector's record QF-35 under manual §13.7, so that a panel's history can be followed from the bed to the wall it ended up in. Neither the release nor the closing of the traveler waits on it, because QF-35 is completed by the erector after the panel has shipped. "Not returned" is a legitimate and final entry, and the quality manager writes it rather than leaving the line blank.

QF-14 Bed and form check#

Form layout

Header: Bed ____ Cycle no. ____ Date ____ Panels to be cast: slot 1 ____ slot 2 ____ slot 3 ____ slot 4 ____ (serial nos.)

Footer: All slots accepted for steel placement: Yes / No. Exceptions and action: ____ QC inspector ____ date ____ time ____

Procedure of use

1. Perform the check after the bed is set up and before any steel, mesh or embedment is placed. A check made after the steel is in cannot see the liner.
2. Write the measured value in each cell. A tick is not a measurement.
3. Where a slot fails, it is not used until it is corrected and re-checked on a new line of this form.
4. Attach the completed form to the cycle's travelers, so that each panel's record shows the bed it was cast in.
5. Until the [PE TO SET] criteria exist, the inspector records the measured values and refers any doubt to the quality manager; no slot is accepted against a criterion that has not been set.

QF-15 Mesh and embedment placement check#

Form layout

Header: Serial no. ____ Bed / slot ____ Drawing and revision ____ Date ____

Steel:

Mesh:

Embedments:

Footer: Accepted for insert check and pre-pour: Yes / No. Exceptions: ____ QC inspector ____ date ____

Procedure of use

1. Perform after the steel, mesh and embedments are placed and before the lifting insert check.
2. Read every steel designation off the member, not off the bundle label and not from memory.
3. Write measured positions for every embedment. For the shower house floor panel the drains, slopes and sleeves are the items that can never be corrected and can never be inspected at the site, so they get a measured value each, not a tick.
4. Where any line fails, the item does not advance; the failure goes to the quality manager and, if the condition cannot be corrected before the pour, a nonconformance is raised.
5. Attach to the panel's traveler.

QF-16 Lifting insert placement check, and wall panel pick check. HOLD POINT.#

Which section applies. Section 1 applies to items with cast-in lifting inserts, which today are the roof strip and the shower house floor panel. Section 2 applies to wall panels, which have none. No item uses both. Mark the section that does not apply N/A and initial it; a blank section is not an accepted section.

Section 1. Lifting insert placement, before the pour. HOLD POINT.#

Form layout

Header: Serial no. ____ Item: roof strip / floor panel / other ____ Drawing and revision ____ Insert schedule ref. ____ Date ____ Design pick weight ____ lb Number of inserts ____ Per-insert share ____ lb Required capacity [PE TO SET] ____

Pre-pick block, completed later, before the item is lifted:

Footer: HOLD POINT SIGNED: insert placement accepted. QC inspector ____ date ____ time ____

Section 2. Wall panel pick check, before the first lift. HOLD POINT.#

Governed by manual §7.8. Completed for every wall panel, once, before it is lifted out of its slot for the first time. A wall panel carries no cast-in lifting insert; it is picked from the up-facing stud side, flat and face down in the slot, on the forklift with boom attachment (equipment item E-8, manual §4.2).

Header: Serial no. ____ Panel height ____ in Bed / slot ____ Drawing and revision ____ Date ____ Time ____ Design pick weight from QF-13 ____ lb Truck and attachment used ____ Marked capacity at the boom's load centre ____ [KEN TO CONFIRM: no truck or attachment has been bought, so no marked capacity exists]

Footer: HOLD POINT SIGNED: wall panel pick check accepted, first lift authorised. QC inspector ____ date ____ time ____ Provisional method. The pick is not engineered. Items (a) to (g) at manual §7.8 item 9 are open: ____ (initial to confirm read)

Procedure of use

1. Section 1 is performed after QF-15 and before the pre-pour hold point. Nothing is poured over an unsigned insert check.
2. Write the measured position of every insert. Inserts are not sampled.
3. No substitution of insert type is permitted at the bed. A different insert is a design change under manual §3.2.
4. The section 1 pre-pick block is completed before the item is lifted for the first time, and the quality manager authorises the pick.
5. Until the engineer of record has set the insert type, its capacity in 35 pcf cellular concrete established by ASTM E488/E488M pull-out testing in this plant's concrete, the required embedment and the safety factor, no item may be picked on cast-in inserts. This form records that the values are not yet set.
6. Section 2 is performed on every wall panel, at the bed, immediately before the first lift, by the inspector watching the pick — not in the office, not the day before, and not after the panel is out.
7. A wall panel lifted before section 2 is signed has been handled outside the approved method. Raise a nonconformance QF-22 against the panel whether or not it was damaged, because the method is the only control the plant has on this operation.
8. Sign section 2 once per panel. Later moves of the same panel — storage to truck, truck to wall — are made by the same method under §7.8 and do not re-open the hold.
9. Section 2 records a provisional method. The pick weight, the checks and the signature are real records; they are not evidence that the pick is adequate. The engineer of record has not set the attachment points, the suction and dynamic factors, the required truck and attachment capacity, the sling arrangement, or whether the 150 in wall A panel at approximately 879 lb needs a designed cast-in insert instead of a boom pick. Those are manual §7.8 item 9 (a) to (g) and open item OI-58. No number on this line of the form is a capacity.

QF-17 Panel dimensional and surface inspection#

Form layout

Header: Serial no. ____ Type ____ Design length ____ Design width ____ Design thickness ____ Date stripped ____ Date inspected ____

Dimensional:

Surface, finish face and cavity face:

Repair block:

Footer: Result: Accept / Repair and re-inspect / Nonconforming (NCR no. ____). QC inspector ____ date ____

Procedure of use

1. Inspect every panel after stripping. The frequency is each panel, not a sample, until the engineer of record and the third-party inspection agency agree in writing to a sampling plan.
2. Write the measured value in every dimensional cell. The cumulative run tolerance across a wall of panels can only be managed if individual widths are recorded as numbers.
3. Compare the finish face against the accepted reference sample panel kept in the plant. Where no reference panel exists, the inspection is recorded and the panel is held, because there is nothing to compare it to.
4. A defect within the repairable class is repaired only by the written repair procedure, and is re-inspected against the same criterion.
5. A defect outside the repairable class, or any insert or embedment displaced beyond tolerance, is a nonconformance under manual §9 and the disposition is the quality manager's, with the engineer of record's written concurrence where the characteristic is structural.
6. Sketch defect locations on the reverse and, where the defect will inform the acceptance criteria that do not yet exist, photograph it and file the photograph with this form.

QF-18 Shower house assembly, MEP rough-in and cladding inspection#

Form layout

Header: Unit serial no. ____ Model and model number ____ Order ____ Drawing set and revision ____

Section 1, skid:

Section 2, floor panel on the skid:

Section 3, walls, partitions and roof (station 9, the cladding is not installed at this station):

Section 4, MEP rough-in. HOLD POINT, before any cavity fill:

Hold point signature: MEP rough-in accepted, cladding and fill authorised. QC inspector ____ date ____ time ____

Section 5, cladding installation, station 11, after section 4 is signed and before any fill is pumped (manual §7.11 items 6 and 7):

Section 5 signature: Cladding installed and dimensions taken. Cavity fill may now be pumped. QC inspector ____ date ____ time ____

Section 6, cavity fill: Fill date ____ Batch nos. ____ Density readings: see QF-09 Fill complete and verified by ____

Procedure of use

1. Complete sections 1 to 3 as the assembly proceeds, not retrospectively.
2. Section 4 is a hold point. No cladding goes on and no cavity fill is pumped until it is signed. The fill is irreversible and it permanently conceals work that a site inspector will never see; the cladding closes the cavity to view before the fill does.
3. The pressure and continuity tests named in section 4 are performed and recorded on QF-19 before the hold point is signed, not after.
4. Notify the third-party inspection agency of the hold point in accordance with the agency agreement and record the notification.
5. Sections 4, 5 and 6 are completed in that order and the order is not interchangeable. The cladding sheet and the cast skin are the two faces that contain the fill, so the cladding goes on first; with it off, there is nothing for the 30 pcf fill to bear against. The overall dimensions are taken in section 5 because the width is measured over the cladding, and because a fill pumped into an out-of-dimension unit cannot be taken back out.
6. Where any line fails, the item does not advance and a nonconformance is raised.

QF-19 In-plant systems test record#

Form layout

Header: Unit serial no. ____ Model ____ Date(s) of test ____ Codes: NEC 2020 (ARM 24.301.401, MT amendments 210.8(A), 210.8(B), 210.12); UPC 2021 (ARM 24.301.301); IFGC 2021 (ARM 24.301.173) if gas is present

1. Electrical

Circuit schedule (one line per circuit): Ckt no. | Description | OCPD | Conductor | GFCI/AFCI | Continuity | Polarity | Operated | Initials

2. Gas line

No fuel gas piping or fuel gas appliance is installed in this unit: Yes / No If No, complete:

3. Water supply

4. Drain, waste and vent

5. Fixtures

Footer: All systems tests passed: Yes / No. Failures: NCR no. ____ QC inspector ____ date ____ Licensed electrician ____ licence no. ____ Licensed plumber ____ licence no. ____

Procedure of use

1. Perform the rough-in tests before any concealment, including before the cavity fill, and record them here before the QF-18 hold point is signed.
2. Perform the final tests after fixtures and devices are installed, before the final inspection at QF-20.
3. Record the actual test pressure, the duration and the start and end readings. "Passed" without readings is not a test record.
4. Record the identification of every instrument used, from the calibration register QF-21, so that a test can be re-examined if the instrument is later found out of calibration.
5. Any failure is a nonconformance under manual §9. The re-test after correction is recorded on a new line, not by altering the failed line.
6. The gas section is completed as "no gas piping installed" on every current model. It is not deleted, so that the record shows the question was asked.

QF-20 Final unit inspection and release record#

Form layout

Header: Serial no(s). ____ Item type ____ Model and model number ____ Order and customer ____ Drawing set and revision ____ Date ____

Release block:

Procedure of use

1. No item is loaded, shipped, offered for sale or delivered before this form is signed.
2. Every "No" stops the release. A "No" is not overridden by a note; it is resolved, or the item stays.
3. Item 5 is the only place early release is possible, and only on the engineer of record's written acceptance attached to this form. A verbal acceptance is not acceptance.
4. The release signature is the quality manager's alone. If the quality manager performed production work on the item, manual §2.3 independence rule 2 applies and the item is held until a qualified independent signer is available.
5. File this form with the traveler attached. Together they are the item's complete conformance record.
6. Item 15 checks that the blank QF-35 is in the pack. The release does not wait on a completed QF-35 and cannot: the erector completes it after the panels have shipped. The plant's duty at release is to issue the blank with the installation instructions it records against, and nothing more (manual §13.7 item 3).

PART 4. EQUIPMENT AND PROGRAM ADMINISTRATION#

QF-21 Calibration register#

Form layout

Out-of-calibration finding block, required by manual §8.8 item 4:

Procedure of use

1. Every instrument used to accept product is on this register before it is used. An instrument not on the register may not be used for an acceptance measurement.
2. Calibration is performed by an outside service or the manufacturer, traceable to nationally recognized standards, and the certificate is filed and referenced here.
3. The batching devices are additionally checked before the first batch of each production run, per ACI 523.1R-06 §5.2, and that check is recorded on QF-09, not here.
4. An instrument past its due date is tagged DO NOT USE and removed from service that day.
5. When an instrument is found out of calibration, the out-of-calibration block is mandatory. The quality manager identifies every product accepted with that instrument since its last good calibration, evaluates it, and dispositions it under §9. Recalibrating the instrument does not close the finding.
6. The register is reviewed at every internal audit against the instruments actually on the floor.

QF-22 Nonconformance report#

Form layout

Disposition:

Re-inspection:

Closure:

Procedure of use

1. Anyone who finds or suspects a nonconformance stops the item and notifies the QC inspector. The QC inspector opens this report and tags and moves the item to the hold area.
2. Record the measured actual condition, not "out of tolerance". The measured value is what lets the engineer of record disposition it.
3. The quality manager signs the disposition, and does not disposition work they performed themselves.
4. Rework and repair are re-inspected against the original criterion by the original inspection, and the result is recorded here and on the traveler.
5. Scrapped items are destroyed or defaced so they cannot re-enter production, and the serial number is voided on QF-28 so it can never appear on a label or an insignia application.
6. Where released product is affected, the customer and the third-party inspection agency are notified immediately and the notification dates are recorded here.
7. Review every open NCR at each internal audit; review the set of them for pattern.

QF-23 Corrective action report (POCA)#

Form layout

Procedure of use

1. Open a report whenever any trigger at manual §2.9 item 1 is met.
2. The investigation is written before the cause. A cause stated without an investigation is a guess and produces a corrective action that does not work.
3. A corrective action that changes how the plant works requires a revision of this manual under §3.5 before the change is made, and the revision number is recorded here.
4. The owner does not sign the closure until the verification evidence is attached. An unverified corrective action is an open corrective action.
5. Open reports are reviewed at every internal audit and at the annual management review.

QF-24 Internal audit report#

Form layout

Header: Audit no. ____ Date(s) ____ Auditor ____ Areas audited ____ Period covered ____

Footer: Findings raised: ____ CARs opened: ____ Auditor ____ date ____ Quality manager ____ date ____

Procedure of use

1. Audit quarterly, and additionally whenever a corrective action, an agency deficiency or a bureau finding suggests a system failure.
2. Examine records, not opinions. Every finding carries objective evidence: a record, a serial number, an observation with a date.
3. Item 11 is performed at every audit. It is the single best test of whether the record system works.
4. An auditor does not audit their own work. Where the quality manager's own area is the subject, the independent auditor named in manual §2.7 item 4 performs that part.
5. Findings are closed through corrective action QF-23, not by a note on this report.

QF-25 Management review minutes#

Form layout

Header: Review date ____ Present: owner ____ quality manager ____ plant manager ____ others ____ Period reviewed ____

Footer: Manual revision required: Yes, rev. ____ / No. Owner signature ____ date ____

Procedure of use

1. Hold the review once each calendar year and minute it on this form.
2. Item 9 is the point of the review. If the plant is working differently from this manual, the manual is revised under §3.5 and the practice does not continue in the meantime.
3. Any decision to change how the plant works produces a manual revision before the change is made.
4. The owner signs the minutes. Unsigned minutes are not a management review.

QF-26 Training record#

Form layout

Header: Name ____ Role(s) ____ Date engaged ____ Stations authorised to work ____ Forms authorised to sign ____

Qualifications held:

Training delivered:

Authorisation block: Authorised to perform and sign: ____ Authorised by quality manager ____ date ____ Withdrawn ____ date ____ reason ____

Procedure of use

1. Open a sheet before a person performs any task that affects product quality.
2. Record training to a specific drawing revision when a revised document is issued, because manual §2.6 item 2 requires that training before the revision is worked to.
3. Record retraining triggered by a corrective action with the CAR number.
4. Track certification expiry and renew before expiry; the annual management review checks this.
5. A person signs a quality record only for tasks the authorisation block lists. Withdraw the authorisation in writing when a person moves off a station.

QF-27 Insignia and certification label control register#

Form layout

Part 1, Montana insignia (units):

Part 2, third-party agency certification labels (components):

Part 3, month-end report:

Expiry watch: Insignia within 3 months of the 12 month void date: ____ Reported to the owner on ____

Procedure of use

1. Enter every insignia and every label on the day it is received.
2. Store insignia and labels locked. Access is limited to the quality manager and the designated officer. [KEN TO CONFIRM: the locked location and who holds the key.]
3. An insignia is applied only after QF-20 is signed, and only by the manufacturer, per ARM 24.301.1243(2).
4. A certification label is applied only after the plant's release and after every deficiency in the agency's inspection report is corrected, per ICC/MBI 1205 §401.1(15)‡. Labels are obtained only from the agency.
5. Review the register monthly. Report to the owner any insignia within three months of its 12 month void date, because a void insignia is not refunded, not credited and not replaced.
6. Prepare the month-end report from Part 3 and submit it as ICC/MBI 1205 §503.1‡ requires. [KEN TO CONFIRM: recipient, format and due date, agreed in writing with the bureau and the agency.]
7. Report lost or damaged insignia to the bureau in writing. Return or destroy damaged, void and later-found insignia as directed, record the disposal here, and make no duplicates.
8. Reconcile Part 2 against the agency's own issued list at each month end and at each internal audit.

QF-28 Serial number register#

Form layout

Procedure of use

1. Assign serial numbers when the order is released to the floor, in the format at manual §10.1, and print them on the travelers before work starts.
2. Fill in the production columns as the item moves, so the register is a live index into the records.
3. A scrapped item's serial number is marked VOID with the NCR number and is never reissued. A void number must never appear on a certification label or an insignia application.
4. Reconcile against the insignia and label register QF-27 at each month end and at each internal audit.
5. The register is the starting point for any traceability enquiry from the bureau, the agency or a customer.

QF-29 Document and drawing control register#

Form layout

Part 1, controlled documents:

Part 2, order release check, manual §3.3:

Procedure of use

1. Register a document before it is issued to the floor. An unregistered document is not a construction document.
2. Stamp each issued copy CONTROLLED COPY with its location and issue date, and record the issue here.
3. On a revision, issue the new revision to every location listed, physically retrieve every superseded copy, destroy it or mark it VOID REFERENCE ONLY, and record the retrieval. An uncontrolled printout or a photograph of a drawing is not a construction document and may not be built from.
4. Complete Part 2 before every order is released to the floor. If any check fails, do not release the order, and raise the discrepancy with the engineer of record in writing.
5. The register is checked at every internal audit against the documents actually on the floor.

QF-30 Manual revision record#

Form layout

Procedure of use

1. Anyone may propose a change; only the quality manager may issue a revision.
2. Mark the changed text in the revision, update the manual's revision history at §0.7 and the cross-reference tables at §0.4 and §0.5 if section numbering moved.
3. Submit one copy of the revised manual to the bureau with the review fee required by ARM 24.301.1261, and do not work to the revision until the bureau approves it.
4. On approval, issue to every location on QF-29, retrieve and destroy or void every superseded copy including the printed plant copy, and record the retrieval.
5. A change made on the floor before the revision is approved is a violation of this manual and of ARM 24.301.1223(3), and it is the classic way an approved plant drifts out of compliance.

QF-31 Customer complaint and field service record#

Form layout

Procedure of use

1. Record a complaint on the day it is received, whatever channel it came through.
2. Investigate promptly and respond in writing. A substantiated complaint opens a corrective action.
3. File the record back against the item's serial number so that the unit's history is complete.
4. Where the remedy would alter or revise a unit bearing an insignia, ARM 24.301.1249 applies: an application goes to the bureau before the work, and a bureau inspection is requested on completion. An alteration made without that application can void the insignia and the plan review.
5. Review complaints at the internal audit and at the management review.

PART 5. STORAGE, SHIPPING AND SITE#

QF-32 Storage and stacking record#

Form layout

Header: Location ____ Date ____ Stack limit [PE TO SET] ____ Support points [PE TO SET: manual §7.8 item 9(g); the handling instruction at §7.8 does not yet carry them] ____

Procedure of use

1. Record every item into storage on the day it is stored, so that any panel can be found from its serial number.
2. Wall panels are moved into and out of storage by the method at manual §7.8, on the forklift boom. Until the engineer of record sets a stack limit and the dunnage and support point positions (§7.8 item 9(g)), product is not stacked.
3. Inspect every item for damage before it is loaded, and record the condition. Damage found is a nonconformance.
4. Apply the same rules to storage at any point other than the plant, and state them in the installation instructions so that the erector is bound by them on site.

QF-33 Loading and unloading manifest#

Form layout

Header: Manifest no. ____ Order ____ Customer and site ____ Date ____ Carrier and driver ____ Vehicle ____ Permit no. (oversize) ____

Load list:

Transport data:

Unloading instructions to the erector:

Footer: Production lead ____ date ____ Carrier ____ date ____

Procedure of use

1. Prepare a manifest for every shipment, before loading.
2. Prepare the unloading section jointly with the erector where ICC/MBI 1200 §704.1‡ requires, so that the crane and the rigging on site match the picks the product needs.
3. Check every item for damage before loading and record it on QF-32.
4. The driver signs the manifest at loading. A copy travels with the load and is handed to the receiver.
5. Securement complies with 49 CFR 393 Subpart I; a load that cannot be secured as the manifest states does not leave.

QF-34 Delivery and receipt record#

Form layout

Header: Manifest no. ____ Order ____ Site ____ Date and time of arrival ____

Procedure of use

1. The receiver inspects every item before signing and describes any damage rather than writing "damaged".
2. Photograph any damage at the site, before unloading if the damage is on the load.
3. Report damage to the plant the same day; the quality manager raises a nonconformance and decides whether the item can be used, repaired on site or must be replaced.
4. Return the signed record to the plant and file it with the order, so that the item's history is complete from the bed to the site.
5. Where the panels are to be stood on the site, the erection record QF-35 travels in the same pack and is completed by the erector after unloading. This form ends the plant's chain of custody at the tailgate; QF-35 picks it up at the wall. Manual §13.7.

QF-35 Panel erection record, on site#

Whose record this is, and what the plant is answerable for. The plant does not erect the house and does not inspect the erection. This form is not a plant inspection and it is not a hold point; no station of §4.3 covers it and §7.13 row 23 marks it expressly as a record made off the plant's premises by somebody who does not work for the plant. What the plant is answerable for is narrow and it is stated so that nobody has to guess:

1. Issuing it. The blank goes out with every shipment of panels for site erection, with the installation instructions it records against. Failing to issue it is a nonconformance against the process under §9.
2. The instruction behind it. Every criterion on this form is the plant's to supply through the engineer of record, in the installation instructions at §13. Where a criterion is marked [PE TO SET] the erector cannot be asked to work to it, and the honest position is that the erector records the value and the plant carries the gap.
3. Acting on what comes back. A returned record that reports damage to a plant-made item, a panel that does not match the key plan, or a wall that will not close to length, is fed into §9 as a nonconformance against the plant's product and, where §2.9 item 3 applies, to the customer and the third-party inspection agency.
4. Not certifying it. The plant does not sign, adopt or vouch for the erector's values, and a completed QF-35 on file is not evidence that the building was erected correctly. It is evidence of what the erector recorded.

[KEN TO CONFIRM: whether returning a completed QF-35 is a condition of sale, that is, whether the sale agreement obliges the buyer or the buyer's erector to complete it and send it back, and what the plant does when it is not returned. This is a commercial decision and it is Ken's, not the engineer's and not the quality manager's. Until Ken makes it, the plant issues the blank, asks for it back, records on QF-20 that it was issued, and records on this form's plant-use block whether it came back. The plant does not hold, delay or refuse anything on account of a record it has no power to compel.]

Form layout

Header: Erection record no. ____ Order ____ Manifest no(s). ____ Site address ____ Building / model ____ Key plan and panel schedule, revision ____ Installation instruction, revision ____ Erector (company) ____ Site supervisor (print) ____ Start date ____ Completion date ____

Section 1, before the first panel is stood:

Section 2, panel by panel. One line per panel, written as it is set:

Criteria for section 2: [PE TO SET: the out of plumb limit, the joint gap range, the joint screw size, count and pattern through the mating edge studs, and the slab anchor type, size, embedment and spacing. §13.2, §13.5, open items OI-63 and OI-65. The design model carries 8 screws per joint and 2 anchors per panel. Those are assumptions in a drawing model, they are not a design, and they are not a criterion on this form.]

Section 3, cumulative run. One line per wall, and this is the section the others do not cover:

Criterion for section 3: [PE TO SET: the cumulative run tolerance across a wall of panels, §7.9 and §13.5, open items OI-55 and OI-65. No adopted standard sets it and no number exists.] Measure and write every joint gap and the built length of every wall as the wall goes up, and report a wall that is running long or short while there are still joints left to correct it in. Do not absorb the difference silently in the last joint.

Section 4, tying the tops:

Section 5, the rough-in and the fill. This is the irreversible one:

Section 6, damage and anything that goes back to the plant:

Signature block:

Footer: QF-35 Rev. __ | MT-QAM Rev. __ | page __ of __

Procedure of use

1. The quality manager issues a blank QF-35 with every shipment of panels that will be stood on a site, and records the issue on the release record QF-20. It goes out with the installation instructions, because the form and the instruction only make sense together.
2. The erector completes it, not the plant. Nobody from the plant writes a value on sections 1 to 6 and nobody from the plant signs the erector's declaration. A plant employee who fills in this form has made a record of work they did not do, which is the same offence as signing another person's traveler line.
3. Entries are made in ink, at the site, as the work is done, by the person who did it. Rules A.0 2 to 7 apply to this form in the erector's hands exactly as they apply to a plant form in the plant's hands, and they are printed on the form so that an erector who has never seen this manual still knows them.
4. Write the measured value, never a tick, above all in sections 2 and 3. A tick on a cumulative run line is worth nothing: the whole reason for section 3 is the number.
5. Several criteria on this form are [PE TO SET]. That does not make the line optional. Where a criterion is not set, the erector still measures and writes the value; the value is the record, and it is the evidence the engineer of record will use when the tolerance is finally set. A line left blank because "there was nothing to check it against" is a blank field, which A.0 rule 4 does not allow.
6. Section 5 is the line that cannot be recovered. A cavity filled before the authority having jurisdiction has approved the rough-in has destroyed the inspection, and the work has to be opened again. The requirement is also carried in bold on its own page in the installation instructions at §13.6.
7. Return the completed record to the plant with, or after, QF-34. The quality manager files it behind QF-34, cross-references it from each panel's traveler QF-13, and raises a nonconformance QF-22 for anything in section 6 that is against a plant-made item.
8. A record that is not returned is recorded as not returned, with the date. The plant does not fabricate, complete or estimate an entry on a form it did not fill in, and it does not sign the erector's declaration on the erector's behalf under any circumstances.

END OF APPENDIX A#

Forms QF-01 through QF-35 are the complete set of forms used in this program. No form is used in the plant that is not in this appendix, and no form in this appendix is used in a way other than the procedure stated with it.

One of the thirty-five is not filled in by this plant. QF-35 is completed and signed on a customer's site by the erector's site supervisor, under manual §13.7. It is in this appendix because the plant issues it, it is a controlled document on QF-29, and the completed record is filed and retained as a quality record. It is not in this appendix because a plant employee signs it, and none may.