PMEL Forum

My supervisor asked me to do an over the shoulder audit on the calibration technicians.
We really don't have a quality department yet. . . but we want to start the process and begin with over the shoulder audits.  Myself and most of our techicians have been PMEL trained so they know what they are doing, or should be doing.  We have a full service lab covering RF/microwave to electronics to physical and demensional equipment.  I've been through enough of these over the shoulder quality checks myself to know the basic questions about the proceedure being used, equipment substitution, are you formally trained on this piece of equipment. . . etc, etc. 
However. . . I was wondering if anyone had a nice template of questions already put together you might be willing to share with me. 
Thanks for reading my post. 
Scott.

When I was in the A. F. , our quality guys would sit down with us and actually watch us go through a calibration/proceedure step by step.  I think I want to impliment this process or something like it sometime in the future. . . but what I am referring to here is just a quick surprise check list. . . . Here is what I have put together so far:

Impromptu (over the shoulder) calibration technician quality audit check list. 

Technician:             Section:            Date:

Auditor:

Calibration, Repair, Troubleshooting:

What procedure is being used? :

Is the procedure current? :

Is the technician formally trained on this piece of equipment? :

If applicable, E. S. D.  practices being followed? :

When was the last time the technicians E. S. D.  strap was tested? :

Is the proper test equipment being used? :

Is the technicians work space generally neat and clutter free? :

Can you think of anything to add to this list?

I would get rid of the ESD questions. It's clownish. It has to be the most overrated concern in the business and it doesn't really add any value to the audit. Stick to technical questions and try to get a feel if the technician has an understanding of what he is really doing and not just pushing buttons. Any auditor asking me questions about ESD would lose any credibility he may have had.

Is the calibration label complete?

Is the environment within limits at time of calibration?

I have always found people are a bit more prone to choke up when undergoing these audits.
My preference would be to say little during the testing process, let the tech talk all they want. 
Discuss you observations/concerns/praise afterwards.

Well E.  S.  D.   practices are of paramount importance where I work, so I need to put that in there.   It's a HUGE deal here so I think that part needs to stay, especially if I walk up during the troubleshooting process and a piece of gear is actually open and being worked on. 
I like the environmental conditions question.  .  .  that's a good one. 
Discuss your observations/concerns/praise afterwards. . . . I like that also.  Always a good thing to give positive and constructive feedback. 
This list will be evolving so I really appreciate any constructive input.  .  .  I'll keep checking in.  

Do your technicians have a checklist they follow? I'd start with that.

They follow regular 33K- proceedures for each calibration.
We also have our own quality manual and a few years ago I wrote an SOP for calibration technicians that they have all signed off on. 
Yes those are some of the guidelines I will be making sure they are following. 

The SOP is what you probably want to focus on. Sit down with it and write out a checklist for your technicians to follow in order to standardize the process across your lab. When you do that, you will have your QA checklist. 

Here is a checklist we use with new trainees, but would also be great for an over the shoulder.

The Calibration Checklist The following items need to be accomplished by all technicians.
*** Note: This checklist is not all-inclusive. ***
A. PRIOR TO BEGINNING CALIBRATION
1. Select an item from awaiting maintenance (AWM) listing; highest priority, oldest item.
2. Ensure that you are task certified/qualified in your training records for the "calibration" of the item you are certifying, and (as a minimum) opened up on the "use" of all standards used during your calibration process.
3. Obtain item from awaiting maintenance location.
a. Verify equipment condition. (Compliance with 33-1-27 Owner/User Responsibilities)
b. Verify all required technical data and accessories are present.
c. If discrepancies are noted, inform the scheduler and supervisor.
4. Verify accuracy PAMS hand receipt against item and CMS/33K-1-100-2.
a. PAMS bar code label (AFTO 65/66) present, intact, not a FOD hazard, and numbers correlate.
b. K100 and Item Part Number correct including options, modifications and series number.
c. Verify applicable specifications in AFCAV.
d. Serial numbers complete and match character for character.
e. Work Unit Code (WUC); ensure nomenclature and manufacturer are correct.
f. Check data against weapons summary if appropriate (F-16/JEN).
g. Is item part of a See Individual Components Listing (SICL) system?
5. Process item to in work (INW) status prior to beginning maintenance.
6. Check item for foreign object contamination. (Shake test)
7. Check item for T.O. 33-1-32 Input Power Wiring requirements.
a. Integral power cord: Visual inspection, fuse placement in circuitry, and ground continuity check.
b. Detachable power cord: Proper power cord wiring, ground continuity check, and fuse placement in circuitry.
c. Verify fuse characteristics IAW TO 1-1A-14 regarding correct voltage/current rating and blow time characteristics.
8. Check item for TO 00-25-234 General Maintenance Practices' compliance.
a. Cuts or cracks in power cords.
b. Proper strain relief. i.e., grommets
c. Fuse holders not loose or cracked and properly retains fuse when removed.
9. Verify currency of tech data using Air Force T.O. index (https://toindex-s.robins.af.mil/toindex/)
10. Read and become familiar with the entire calibration procedure prior to beginning calibration.
a. Become familiar with and understand implications of all warnings, cautions, and notes.
11. Ensure all standards under equipment requirements are available, serviceable, and not overdue and that limitations indicated will not adversely affect the calibration process.
12. If substituting standards, verify beforehand that test accuracy ratios are maintained; be prepared to support and prove substitutions
13. Ensure that all warm-up/soak times are observed.
14. Ensure that laboratory environmental conditions are met. (73 6, 20 to 50%RH)
15. Gather required equipment, cables, adapters, calibration charts, etc. for calibration.
16. Ensure accuracy of loads and cables, especially if specifically identified by part number or accuracy in K-Procedure "Equipment Requirements:"
17. Make any preliminary standardization or adjustments on unit under test and on standards utilized during calibration I.A.W. applicable maintenance data. ("Orange Dot" Pgrm)
18. Check item for an AFTO Form 350, take required corrective action and document form accordingly upon completion.
The Calibration Checklist Last Updated: 20081117
The following items need to be accomplished by all technicians.
*** Note: This checklist is not all-inclusive. ***
B. CALIBRATION PROCESS
1. Follow the procedure in its entirety, step by step, in the order presented, with no unexplained/unauthorized deviations. Verify/validate AFTO 57 information prior to use.
2. Ensure standards requiring certified accessories (i.e., cables and loads) are used accordingly.
3. Comply with all safety requirements while performing calibration.
a. Do not endanger yourself, coworkers, or equipment and use the buddy system at all times.
b. Protect circuitry from over-ranging; read on highest range, output from lowest range.
4. Use applicable calibration factors and charts, mathematical computations, and established sound metrology practices throughout calibration process.
5. If any questions arise about the use, operation, or standardization of equipment consult the applicable maintenance TO.
6. List the ID numbers of all standards used for certification on the hand receipt immediately after use. This list will be used during post calibration (Step 1).
7. If technical deficiencies are identified, prepare and submit an AFTO Form 22. C. POST CALIBRATION
1. Properly enter MDC data into PAMS including a complete list of standards used.
a. With "Calibration Certificates", generate an "Out of Tolerance Letter" if necessary as per T.O. 00-20-14 para. 5.7.2.
2. Prepare certification label. (Note: Use Limited Certification Label for NHA, CBU and NPC)
a. Identification Number: Ensure ID number matches PAMS bar code label and PMEL hand receipt; obtain OWC from hand receipt. Document WRM/MOB if applicable.
b. Authority Block: T.O. or Commercial Data as appropriate.
b. Special Block: Information or Limitation - must include any T.O. directed or user coordinated limitations. Include "Part of ,,SICL end item PN" if appropriate.
** Re-check calibration T.O. for T.O. directed annotations or limitations.

d. Certified By: your K-Stamp or your trainer‟s K-Stamp if you are in training. Initials not authorized!
e. Date Calibrated: the appropriate date calibrated in the YYYY MM DD format.
f. Date Due: Calculated date due in the YYYY MM DD format.
g. User Approval: Appropriate signature for PMEL owned equipment, otherwise blank.
3. Prepare calibration chart as required.
a. Refer to T.O. 00-20-14 5.7 for generation of a Calibration Certificate/Report.
b. Ensure a chart is prepared if calibration procedure directs.
c. Ensure certification label references calibration chart.
4. Prepare other forms (i.e. 250, 255, 256, 350, etc.) I.A.W. applicable directives.
5. Verify physical condition.
a. Cleanliness; remove dirt, grease, corrosion, tape residue.
b. Knobs, feet, dust boots, switches, panel meters, etc. Secure - not cracked, broken, or missing.
c. Check all accompanying cables and accessories. (Condition, back-shell clamps, etc)
d. All numbers and letters are legible.
e. Protective caps placed on exposed connectors; conductive caps if ESD sensitive.
f. All screws and nuts verified present and tight.
g. Connector caps on flight line equipment are physically secured to unit.
h. Old certification label removed, eradicate erroneous ID or serial number etchings as appropriate.
i. Correct discrepancies that affect safety or require internal access.
j. Attach AFTO Form 350 identifying all OWC responsibility maintenance or repairs.
6. Torque wrenches
a. Ensure torque wrench is set to lowest torque setting upon completion of calibration.
7. Check (shake) item for foreign object contamination.
8. Place unit at the appropriate location.

Excellent checklist TSgt. 
I also got your . pdf version in the email. 
Thanks for sharing this with me. . . it will be a great help. 

what about updating the data base (pams for the AF) or master equipment list