Quality Management System
Our Quality Management System (QMS) is built on a foundation of continuous improvement, risk-based thinking, and total process control. MetalCore operates under ISO 9001:2015, AS9100 Rev D, and IATF 16949 frameworks, ensuring traceability, defect prevention, and consistent part quality across all production volumes.
Core QMS Principles
- Full material & process traceability from raw stock to finished part
- Documented procedures for non-conformance, containment, and CAPA
- Regular internal audits, management reviews, and KPI tracking
- Advanced root cause analysis using 8D, 5-Why, and Fishbone methodologies
- Dedicated QA engineering team supporting NPI through mass production
PPAP Process & Submission Levels
The Production Part Approval Process (PPAP) is a standardized method to verify that our manufacturing process can consistently produce parts meeting all customer engineering drawings, specifications, and requirements. We support all AIAG PPAP submission levels and maintain up-to-date process controls.
| Level | Submission Requirements | Typical Use Case |
|---|---|---|
| 1 | PSW (Part Submission Warrant) only | Customer approval only |
| 2 | PSW + Samples + Limited supporting data | Customer specifies |
| 3 | PSW + Samples + Full supporting documentation | Default for most programs |
| 4 | PSW + Customer specific requirements | Special agreements |
| 5 | PSW + Samples + Full docs reviewed at supplier facility | On-site approval only |
PPAP Documentation & 18 Elements
Our PPAP package is compiled by dedicated quality engineers and includes all 18 AIAG elements, tailored to your specific program requirements:
Standard PPAP Deliverables
- Design Documentation & Engineering Change Documents
- Customer Engineering Approval (if required)
- DFMEA / PFMEA (Design & Process Failure Mode Analysis)
- Process Flow Diagram & Control Plan
- Measurement System Analysis (MSA/Gage R&R)
- Dimensional Results & First Article Inspection (FAI)
- Material & Performance Test Reports
- Initial Process Studies (Cpk/Ppk ≥ 1.33 or 1.67)
- Qualified Laboratory Documentation & Part Submission Warrant
All documentation is maintained in our digital QMS platform with version control, audit trails, and instant retrieval for customer or third-party audits.
Inspection, Testing & Calibration
MetalCore operates a fully accredited in-house metrology lab supporting precision verification at every production stage. Our inspection protocols align with ASME Y14.5, ISO 1101, and customer-specific standards.
FAI / AS9102
Complete first article inspections with full dimensional traceability
CMM & 3D Scanning
Multi-axis coordinate measuring machines & optical metrology
SPC & Statistical Analysis
Real-time process monitoring with automated control charts
Calibration Lab
ISO 17025-aligned calibration for all inspection equipment
Non-conforming material is strictly controlled via quarantine, MRB review, and disposition (use-as-is, rework, or scrap) with full customer notification when required.
Quality Certifications & Compliance
MetalCore Manufacturing maintains active third-party certifications across multiple industries. All certificates are publicly verifiable and renewed through rigorous surveillance audits.
ISO 9001:2015
Quality Management Systems
AS9100 Rev D
Aerospace Quality Standard
IATF 16949
Automotive QMS Requirements
Nadcap (PQMs)
Special Process Accreditation
Need PPAP Documentation or Quality Audit?
Our QA engineering team is ready to support your incoming part approval, provide full PPAP packages, or schedule a facility audit.