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CHARBROIL

QUALITY PLANNINGSUPPLIER HANDBOOK

September 27, 2004Revision: 001

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TABLE OF CONTENTS1.0 GENERAL

1.1 Mission/Vision1.2 Introduction

1.3 Quality Planning Handbook1.4 Language

1.5 Terms & Definitions1.6 Surface Descriptions1.7 Defect Categories2.0 INSPECTION

2.1 Raw Materials2.2 Subcontractors

2.3 Incoming Parts/Components2.4 Gas Train Components2.5 In Process2.6 Packline

2.7 Offline Test & Inspection2.8 Overinspection 12.9 Overinspection 22.10 Toll Gates

2.11 Inspection Frequency2.12 Samples

2.13 Organization and Responsibility

3.0 PRODUCT & PROCESS SPECIFICATIONS

3.1 Categorical Process Quality Specifications3.2 Categorical Material Quality Specifications3.3 Tolerances

3.4 Rust (comment)4.0 TESTING, INTERNAL

4.1 Procedure/Standards

4.2 Measurement Standards/Techniques4.3 Required Tests5.0 TESTING, EXTERNAL

5.1 Product Testing5.2 Transit Testing

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5.3 Materials Testing

5.4 Regulatory Compliance Testing5.5 Customer Specified Testing

5.6 Customer Factory Audit/Process Inspection

6.0 SEGREGATION

6.1 Nonconformance6.2 Corrective Action7.0 TRACEABILITY

7.1 Protocol

7.2 Record Keeping

8.0 DOCUMENTATION

8.1 VS1-SP

8.2 Live Fire Quality Planning Handbook8.3 Part/Material Prints, Specifications8.4 Live Fire Inspection Reports8.5 Customer Inspection Reports8.6 Weekly Quality Reports8.7 Certifications

8.8 Other Documents9.0 REFERENCE

9.1 References9.2 RevisionsAPPENDIX A

Supplier ChecklistAPPENDIX B

Signature Page

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1.1 MISSION / VISION

MISSION

• • • • •

To facilitate the flawless execution of all operational activities by:

Providing leadership for product quality excellence.Furnishing technical expertise across the business.

Actively pursuing an agenda of continuous improvement initiatives.

Assessing, measuring, reporting and improving quality performance metrics.Ensuring a relentless focus on product and user safety.

VISION

To provide superior service to our customers through effective, innovative and timelyquality planning, control and improvement activities, in support of the overall mission of

Charbroil.

1.2 INTRODUCTION

Charbroil recognizes it’s responsibility as a provider of quality products/services. To this end,Charbroil has developed and documented a quality management system including the Live Firecategory of products. The quality system complies with the international standard ISO 9001-2000, quality management systems – requirements. This manual provides comprehensiveevidence to all customers, suppliers and employees of what specific controls are implementedto ensure product/service quality.

This manual also governs the creation of quality-related documents and quality relatedactivities. It will be revised as necessary, to reflect the quality system currently in use. It isissued on a controlled basis to all internal functions affected by the quality system and on anuncontrolled copy basis to suppliers. It may be issued to customers if a need for them to have itexists.

This document serves as the official guide, instruction and quality specification to ensurecustomer satisfaction within all levels of Charbroil-Live Fire product development and

production. Certain processes and parameters listed in this document will not necessarily applyto all Live Fire products. There may be product specific requirements that fall outside the scopeof this document. Those requirements will be addressed in a separate product specificdocument.

1.3

QUALITY PLANNING HANDBOOK1.3.1 OBJECTIVE

The objective of this document is to provide a single source that contains all Charbroil-Live Firequality requirements for all of its products and suppliers. It’s intent to serve as the top level ofrequirement and specification detail and contains at the least the minimum requirements forany new or existing Live Fire product. As new products are developed, quality criteria will beevaluated and added to this handbook as necessary. Live Fire QA Manager will ensure latestversion is available to each supplier via the Charbroil-Live Fire Extranet.1.3.2 VS1-SP AND THE QUALITY PLANNING HANDBOOK

It is the suppliers responsibility to obtain, read and comply with both VS1-SP (Vendor

Specification 1 – Sourced Products) and the QUALITY PLANNING HANDBOOK. Each supplieris required to sign and return the signature page from both documents to the Live Fire SourcingManager before he is allowed to produce product for Live Fire. Not only does the QUALITYPLANNING HANDBOOK provide specific details for carrying out the directives and

requirements listed in VS1-SP, it also lists other requirements, specifications and practices thatare required in order to produce Live Fire products. Failure to comply with either of thesedocuments could results in fines or termination as an approved Live Fire supplier.

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1.4 LANGUAGE

All documents (unless otherwise specified) are to be translated into English. Suppliers are

permitted to maintain documents in their native language but anything that has the possibility ofbeing communicated with anyone in the Live Fire group, the customer, certification agencies, etcmust be in English.

1.5 TERMS & DEFINITIONS

The degree to which coatings stick to steel or other components.American National Standards Institute

A compilation of parts or components that make up a larger part of thefinished product.

The process of building or putting together parts to make or complete afinished product.

American Society for Testing and MaterialsAmerican Society for QualityAcceptable Quality Level

A defect usually found in sheet or rod steel enamels due to the liberationof gasses during firing of the enamel.

The act of testing a product to determine the durability and performanceof coatings under “real world” conditions. “Real world” means building afire and operating the unit as a consumer would. This includes simulatingany extreme conditions that could occur.

Cast steel alloys with greater than 2% carbon and 1% to 3% Silicon. Alsocalled “gray” iron, “ductile” or “malleable” iron.

Criteria for Rejection – Model specific quality or engineering requirementsthat must be met in addition to those listed in this document.

Color, Texture, and Shade on any part must match these parameters onany and all other parts. They must also match any specified pantonespecifications.

A manufactured part or assembly that is used to make a finished product.A common metal, reddish, ductile, malleable and tenacious, an excellent

ADHESIONANSI

ASSEMBLY (1)ASSEMBLY (2)ASTMASQAQL

BOILINGBURN TEST

CAST IRONCFR

COLOR MATCHCOMPONENTCOPPER

conductor of heat and electricity.

COUNTER SIGNA complete off tool sample approved by the customer.CROSS HATCHA set of parallel scribe lines in a painted surface followed by a set of

overlaying scribe lines perpendicular to the first set designed to exposebare metal to determine the level of adhesion using the ASTM tapemethod for coating adhesion.

CRSCold Rolled SteelCSACanadian Standards Association – Certifying agency for products

containing gas components.

DIRECT IMPORT (DI)A customer specific program where finished product is shipped directly

from the supplier to the customer or his warehouses.

END OF LINE (E.O.L.)End of PacklineEPAU.S. Environmental Protection AgencyFDAU.S. Food & Drug AdministrationFIREDThe baking or drying of enamel on a steel surface.

FIRST TIER SUPPLIERThe direct supplier of finished products to Live Fire or its customers.HRSHot Rolled SteelIMInstruction/Assembly ManualINNERPACKPacking material used to secure product components and provide

protection during transit.

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IQC

LIQUID PAINT

MASS PRODUCTIONMIL STD 105MIL THICKNESSMSDS

ORANGE PEELOSHA

PACKLINEPANTONEPHOSPHATEPLATINGPORCELAINPOWDER COATPOP

PRETREATMENTRUST

SAE

SAGGINGSPOT WELDSUBCONTRACTORSUPPLIERTACK WELDTAGGED PART

UV (Ultraviolet)

VENDORVS1-SP

Incoming Quality Control (Inspection)

A surface coating that is liquid when applied, dipped or sprayed.Continuous stable off-tool production of parts.

U.S. Military Standard used to determine sample size and reject rate.The thickness of paint or enamel coating measured in thousandths of aninch.

Material Safety Data Sheet This document contains certain informationspecified by the U.S. government regarding chemical content, hazardoussubstances, safe handling and disposal requirements.

An irregular wavy surface, similar to the surface texture of an orange.U.S. Occupational Safety & Health Administration

The process of adding all finished components and parts to the productcarton just prior to shipping.

A set of standard colors for printing, each of which is specified by aunique number.

A salt or an ester of phosphoric acid used in one of the final stages of pre-treatment to help inhibit rust generation and promote paint adhesion.The process of electrochemically depositing a chemical compound on asurface to achieve a layer that helps to seal the substrate, is decorativeand durable.

A cobalt based coating material that when applied and cured will providea strong glass like surface layer that is relatively impervious to high heat,moisture, and other atmospheric conditions.

A surface coating that is dry or in powder form when applied or sprayedPoint Of Purchase – Color sticker or card showing features of the unit.Usually applied with adhesive to the front of unit.

The process of cleaning and preparing metal parts for painting, plating orcoating.

1.Any of various powdery or scaly reddish-brown or reddish-yellowhydrated ferric oxides formed on iron and iron-containing materials bylow-temperature oxidation in the presence of water. 2.Any of variousmetallic coatings, especially oxides, formed by corrosion. 3.A stain orcoating resembling iron rust. 4.Deterioration, as of ability, resulting frominactivity or neglect.

Society of Automotive Engineers

Flowing of enamel on ware that is fired that produces straight or loopedwaves (similar to paint runs).

Resistance Spot Welding (RSW). The application of electric current andmechanical pressure to create a weld between two pieces of metal.Component or sub-process supplier that feeds designated Live Firesuppliers.

Vendor or factory that is the direct supplier of finished products to LiveFire.

To tack one piece of metal to another with drops of welding rod or weldingwire.

A production part that has been inspected, approved and tagged by QC.The tag should be attached to the part and denotes that it is an approvedpart.

Ultraviolet light or the ultraviolet part of the spectrum. Provides

accelerated life testing by concentrating UV light on a specific part orarea.

(See Supplier)

Vendor Specification 1 – Sourced Products

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WARRANTY KITWELD BEADWELD SPLATTERWIP

When a part is designated as a warranty replacement part, all associatedhardware or other parts that are required to install the part are included aspart of the “warranty kit”.

A line of continuously applied ductile material, such as Welding wire orrod.

Beads of solder or welding rod that scatter away from weld spot, usuallysticking to other undesirable locations on the welded pieces.

Work In process – Unfinished parts or components waiting to go to thenext process.

1.6 SURFACE DESCRIPTIONS

Any surface in constant contact with eyes of the user. For devices

used for cooking with the user in “cooking position” standing 36” away from unit.For heating devices, with the user in normal “viewing position” standing 26” awayfrom unit.

Any surface that may be partially hidden but can be seen. For

devices used for cooking with the user in “cooking position” standing 36” awayfrom unit. For heating devices, with the user in normal “viewing position”standing 26” away from unit.

Any surface not seen after assembly. For devices used for cooking

with the user in “cooking position” standing 36” away from unit. For heatingdevices, with the user in normal “viewing position” standing 26” away from unit.

A SURFACE

B SURFACE

C SURFACE

1.7 DEFECT CATEGORIES

Unsafe to person or property. Affects proper use, operation and/or certification ofunit.

Possible unsafe condition. Possible detriment to fit & function. Major cosmeticdefect.

Small cosmetic defect or small irregularities on surface. Does not affect fit &function.

CRITICALMAJORMINOR

2.0 INSPECTIONINSPECTION LEVELS –Live Fire requires that several levels of inspection be in place to ensureproduct and process integrity during development and production. Some inspection frequencies arelisted in individual sections. These will be listed in further detail in the inspection frequency section.

2.1 RAW MATERIALS

Raw materials include any material used to make parts or components that eventually go into thefinished product.

2.1.1 All raw materials are to be inspected prior to use regardless of whether they are used by

the subcontractor or supplier.

2.1.2 If used by the subcontractor, it is the responsibility of the supplier to determine the

sample frequency (unless they are designated as a critical component by Live Fire).

2.1.3 The supplier or subcontractor must have adequate resources in place to perform this

inspection and have processes in place to ensure nonconforming material is quarantinedand segregated from acceptable material.

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2.1.4 Raw materials that are supplied directly to the supplier must be inspected at a rate

based on sampling charts in section 2.11.

2.2 SUBCONTRACTORS

Subcontractors are suppliers or factories that supply parts to the Live Fire supplier. They include butare not limited to fabricators, welders, coaters or sub-component manufacturers.

2.2.1 Subcontractors must be approved and inspected on a periodic basis by the supplier.

The supplier is required to provide Live Fire with a list of approved subcontractors foreach project and report their findings on subcontractor process capability, quality

assurance, quality control measures and technical capability to Live Fire QA & SourcingManagers.

2.2.2 Certain critical sub-processes require direct inspection and approval by Live Fire before

they can be approved to supply parts or processes. Critical sub-processes such as thirdparty painting, porcelain, casting, anodizing, or component manufacturing to name a fewwill be identified by Live Fire personnel for any given product. Once identified, the

supplier and Live Fire representative must periodically visit the subcontractor to monitorprocess stability and quality. The frequency of inspections by the supplier should neverbe less than weekly. Live Fire will make every effort to accompany supplier onsubcontractor visits as often as possible.

2.2.3 All components, are to be inspected before they leave the subcontractor facility. This

inspection can be carried out by subcontractor QC personnel or supplier QC personnelbut must be done at the subcontractor facility.

2.3 INCOMING PARTS/COMPONENTS

Incoming parts or components are defined as any part that is supplied to the Live Fire supplier foreventual inclusion in the finished product.

2.3.1 All components fabricated or assembled that are delivered from a subcontractor are to

be inspected by the suppler before they can be approved for use.

2.3.2 The supplier must have adequate resources in place to perform this inspection and have

processes in place to ensure nonconforming material is quarantined and segregatedfrom acceptable material.

2.3.3 Parts or components that are supplied directly to the supplier must be inspected at a rate

based on sampling charts in section 2.11.

2.4

GAS TRAIN COMPONENTS

2.4.1 Only gas train component suppliers or subcontractors who have been previously2.4.2

approved by Live Fire can be used to supply parts or components for Live Fire products.The list of approved supplier is on file at Live Fire.

All gas component production lots must be tested in accordance with Live Fire

procedures listed in 2004 Cooker and 2004 Gas Fireplace Live Fire Quality Plans andpre-approved BEFORE they can be shipped from component supplier. These qualityplans specify that all lots are to tested prior to shipment from the component factory. Additional random inspections are to be conducted by the supplier once the lot arrives athis location.

Records and results of all pre-shipment tests and random lot inspections are to bemaintained by supplier and available upon request from Live Fire QA Manager.If the supplier is manufacturing Live Fire products that use LP gas, Live Fire QA

Manager will furnish a copy of the appropriate quality plan for gas products prior to startof project.

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2.4.3 2.4.4 2.4.5

2.5 IN PROCESS

In process refers to the manufacturing process. This includes shearing, bending, forming, casting,welding, grinding, painting and assembly. It does not include component or product packing.

2.5.1 In process inspection of all components and parts at all work station/machine/process is

to be conducted non-stop while production is in progress.

2.5.2 Each workstation or process is to have on hand, a QA/QC certified First Piece sample or

drawing. If a First Piece sample is used, it must be dimensionally correct and have allrequired attributes. It is to be tagged as a First Piece sample and must always remain atthe workstation. It must be verified at least twice weekly by QC or engineering.

2.5.3 These samples are to be checked from time to time to make sure they match all required

dimensions and attributes.

2.5.4 During each shift startup, the first pieces off the workstation are to be checked against

the first piece sample. If they do not match, the workstation is not allowed to beginproduction until the differences are resolved. (See section 2.10.3 for an explanation ofFirst Piece and Section 8.8 for an explanation of First Piece documentation.)

2.5.5 Random inspection at each workstation or process must occur at a rate of not less than

1% of daily output.

2.5.6 If any part is found to be out of tolerance, determine nature of defect and if necessary,

stop production at that location and correct. Quarantine and disposition all

nonconforming parts including any that may have moved into WIP storage or to anotherworkstation.

2.5.7 Periodic routine inspection of tools/equipment is required to ensure parts are being

made correctly. This inspection should be conducted at a minimum of once per day ormore frequently if necessary.

2.6 PACKLINE

The packline is where all components and subassemblies are combined with innerpack materials to bepacked into the final product master carton ready for shipping. If all inspection and tests specified inprevious sections are carried out correctly, there should be no nonconforming parts on the packline.

2.6.1 At the beginning of each pack day, one of each part or assembly that will go into final

pack is pulled from lot and verified as being correct dimensionally and functionally.Correct part number should also be verified. This part should be tagged and becomesthe first piece and should be used to judge all subsequent parts against. If subsequentparts do not match the first piece, production should be stopped until the cause can befound, corrected, and all nonconforming parts are removed from packline.

2.6.2 While packline is in operation, QC inspector(s) should periodically inspect parts and

pack method at each station against the first piece to ensure good quality parts arebeing packed and that they are packed correctly.

2.6.3 Perform End-of-line inspections based on MIL-STD 105D using inspection level G II for

cosmetic parameters and S 4 for assembly parameters. A completed and packed unit isto be opened and inspected for missing or damaged parts including correct innerpackand literature. Sampled units must also be inspected for moisture content and sharpedges.

2.6.4 If any part is found to be defective, reject and rework the lot. Inspect for additional

nonconforming parts. If more are found, stop line, evaluate the cause of

nonconformance and perform corrective actions. Remove nonconforming part(s) fromproduction and quarantine.2.7

OFFLINE TEST & INSPECTION

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2.7.1 Components and completed units will be periodically tested as prescribed in Factory QA

Testing Guidelines listed in section 4.0 TESTING, INTERNAL.

2.7.2 These tests will include but are not limited to Adhesion, Burn, Temp Gauge, Sharp

Edge, Transit, Wood Moisture, Salt Fog (spray), Porcelain, Chrome, Anodize, Covers,Glass, Torque, HVR Output, etc.

2.8

OVERINSPECTION 1

2.8.1 Overinspection is the process of verifying supplier factory inspection and adherence to

standards and is carried out by someone other than supplier personnel.

2.8.2 If necessary, to ensure QA, overinspection agents may be required to remain in factory

at all times during Live Fire product fabrication, production and pack. This may includesubcontractors if necessary.

2.8.3 Every effort must be made to perform overinspection at least weekly. It can occur more

if project criticality or situation warrants it. Live Fire personnel may not always be able toperform weekly overinspection, especially during peak production seasons. If this is thecase, Live Fire will notify supplier regarding modified inspection schedule.

2.8.4 In addition to factory inspections, designated overinspection agent is responsible for

verification of supplier document and record keeping and is required to provideoverinspection report to Live Fire QA Manager after each inspection.

2.9 OVERINSPECTION 2

Certain Live Fire customers have their own inspection and test protocols that are used whenever aproduct is designated as DI (Direct Import). Most customer protocols are essentially the same withminor differences. Live Fire and its suppliers are expected to adhere to these protocols in order tosupply product on a DI basis to these customers. This section lists the basic inspection and testsnormally required by DI customers.

* * NOTE * *

Regardless of whether customer inspections and tests are required, the supplier and itssubcontractors must meet ALL applicable Live Fire requirements listed in thisdocument.2.9.1 Factory Pre-Inspection – Live Fire primary suppliers will be subjected to a pre-inspection audit by the customer or it’s agent. This audit consists of a survey of itstechnical capability and quality assurance measures. Normally, human resource

practices are examined during this audit as well. It is possible that the two audits maybe separate and performed by different agencies for the customer. If the supplier failseither of these audits, they must implement corrective actions before they are approvedas a supplier.

2.9.2 Pre-Production Sample – A sample of the product is prepared and sent to the

customer or it’s agent for inspection. The customer will have it’s own set of

requirements that the product must meet. In most cases, this sample must be off tooland be a representative of actual production units. This includes final carton, labels,markings and final literature versions. In some cases it’s possible to send a hand madesample as a pre-production sample. This sample may fail but Live Fire and the supplierwill learn what deficiencies need to be corrected prior to submitting the final productionsample. Live Fire will make every effort to obtain a copy of the customers inspectionand test requirements beforehand. This will be shared with the supplier.

2.9.3 Production Sample – After all deficiencies (if any) have been corrected, a final

complete off tool sample will be submitted to the customer or its agent for approval.

Once approval is granted, the sample may be sent back to the supplier OR a production

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sample could be designated by the customer as the approved sample and must be kepton the production or packline floor as a First Article sample.

2.9.4 Lot inspection or Inspection Advice – Prior to container shipment, the supplier is

required to schedule a container inspection by the customer or it’s agent. The suppliermust have enough units packed in the warehouse and ready to load for each containerscheduled to ship under any given customer P.O. The customer or its agent will inspectseveral units from each completed container lot. These units will be compared to thepublished specifications provided by Live Fire and compared to the First Article sample.

2.10 TOLLGATES

Tollgates are stopping points within the development and production process so Live Fire, the supplierand sometimes the customer can evaluate progress. These are used primarily to stop the process longenough evaluate and if necessary, make adjustments to the product or process but can be used toreevaluate sales, specifications, quality criteria or customer expectations. Requirements for eachtollgate must be satisfied before project is allowed to continue. All tollgates listed below must be builtinto the project timeline.

2.10.1 Initial Evaluation – This is where a prototype or hand made sample is evaluated by Live

Fire. If requested, the sample must be sent to the U.S. for evaluation so the entire LiveFire team can examine it to make sure it meets quality, engineering and marketingspecifications. Evaluation response back to the supplier will be delivered within 72hours.

2.10.2 Component Approval – If the product includes designated critical components such as

gas components, electronics, special coating applications or other special processes,these components or processes must be approved by Live Fire personnel BEFORE use.Other items that require Live Fire approval include cartons and art, Assembly

Instructions and other literature. Specific components or processes that are consideredto be critical or require approval will be communicated to the supplier prior to initial

evaluation. Approval must be complete prior to the completion of the Engineering Pilot.

2.10.3 First Piece (FP)– Off tool individual parts are not normally subjected to first piece

inspection by Live Fire. Since Live Fire contracts or purchases completed units, it doesnot normally require first piece samples. The exception to this is critical components oritems designated by Live Fire to require first piece approval (see 2.9.2 ComponentApproval section). Live Fire suppliers are required to perform first piece inspections onALL parts. Records of these inspections/approvals must be kept on file with the supplierand available upon request by Live Fire. This includes subcontracted parts.

2.10.4 Engineering Pilot Run (EP)– A designated quantity of each mass produced off-tool

part/component is provided for inspection. Each of these parts is examined using

marketing specifications, customer specifications, quality criteria, B.O.M.’s and drawings.Also during this period, each machine and process is examined by Live Fire to

determine its process capability. A list of all nonconforming parts and required processimprovements is generated. The supplier is expected to provide corrective action plansand upon approval of the plan is expected to implement changes.

2.10.5 Production Pilot (PP)– After completion of the EP and FA (see section 2.10.6), a set

number of units are run down the pack line and packed for shipping. During the

production pilot, the pack operation is examined by Live Fire personnel for efficiency andadherence to the published pack method. If necessary, adjustments to the line andmethod are made. Random samples are pulled from the production pilot, assembledand checked for quality. A report of the PP review and inspection will be generated anddistributed by the Live Fire personnel conducting the run.

2.10.6 First Article (FA)– This is a completed sample that is made after the EP has been

successfully completed and all corrective actions have been implemented. It is offproduction tooling and must exactly represent what will be delivered to the Live Fire

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customer including carton, art, literature, required markings including traceability

markings, labels, innerpack and pack method. Live Fire will advise the supplier beforethe start of the production pilot as to who will approve the First Article (LF Asia or LFU.S.A.). It’s probable that more than one sample would be required. Additional samplesmay need to go to the Live Fire customer. Live Fire will inform supplier how many areneeded and where to send the samples.

2.10.7 Lot Inspections – These are required as a random inspection of warehoused quantities

to ensure nothing was missed during all previous inspections listed in SECTION 2.0.This inspection is to be carried out three times per week by supplier QA personnel andas often as possible by designated overinspection agent (see section 2.8).

2.10.8 Modified Inspections – Certain circumstances may require additional or tightened

inspections. These circumstances could include but are not limited to: gas components,electrical components, electronic components or any other component purchased ormanufactured that is designated as critical or that requires special attention.

2.11 INSPECTION FREQUENCY

Typical inspection frequencies generally follow MIL-STD 105/ANSI Z1.4-1993 and are listed in thissection and are shown in charts at the end of this section. Live Fire reserves the right to increase,decrease or change any inspection frequency. Live Fire QA Manager will communicate modifiedinspection frequencies to all involved parties in writing. Certain components by nature, will havemodified inspection and test frequencies. See section 2.10.6 for details on modified inspection, testand the parts/components that use modified inspection or test..

2.11.1 All raw materials to be used in any particular Live Fire product are to be inspected at the

source before they are allowed to leave. Inspection frequency is at the discretion of thesupplier. Supplier accepts full responsibility for raw material inspection at subcontractorlocations.

2.11.2 As raw materials arrive at the fabrication or assembly location, they are to be inspected

by the receiving QA/IQC department based on MIL STD 105 General Level I, AQL .65 .

2.11.3 During fabrication or assembly, part inspections are to be performed at each workstation

based on MIL STD 105 General Level II, AQL .65 . Purchased parts or components areto be inspected by the receiving QA/IQC department at a rate based on MIL STD 105General Level II, AQL .65 . See section 2.10.6 for modified inspections.

2.11.4 Packline inspections are to be based on MIL-STD 105D using inspection level G II for

cosmetic parameters and S 4 for assembly parameters. These inspection samples aresubjected to but not limited to examination for missing or incorrect parts, weld defects,manufacturing defects, paint defects, special testing (i.e. regulator testing, burnertesting, CSA required combustion testing, adhesion, burn, transit, salt fog, etc.) andsharp edge testing.

2.11.5 Overinspection and lot inspection & testing will be conducted on a random basis and

normally performed by someone not associated with the supplier. This inspector willrandomly select and inspect using any of the quality or engineering standards or anyother criteria listed in this document. Every effort must be made to perform

overinspection at least weekly. Live Fire personnel may not always be able to performweekly overinspection, especially during peak production seasons. If this is the case,Live Fire will notify supplier regarding modified inspection schedule.

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MIL STD 105 ANSI/ASQC Z1.4SAMPLE SIZE CODE LETTERSSpecial General Inspection Inspection LOT OR BATCH SIZELevelsLevelsS-1S-2S-3S-4IIIIII28AAAAAABTOAAAAABC915TOAABBBCD1625TO2651911512815011201320110001TOTOTOTOTOTOTOTOTO5090150280500120032001000035000ABBBBCCCCBBBCCCDDDEEEBCCDDEEFFGGHCCDEEFGGHJJKCCDEFGHJKLMNDEFGHJKLMNPQEFGHJKLMNPQR35001TO150000D150001TO500000D500001ANDOVERDSample Acceptible Quality Levels (Normal Inspection)size Sample size1.01.52.54.0code 0.0650.100.150.250.400.65AcReAcReAcReAcReAcReAcReAcReAcReAcReAcReletterA2B301C501D801E130112F20011223G3201122334H500112233456J80011223345678K1250112233456781011L20001122334567810111415M3151223345678101114152122N5001223345678101114152122P8001223345678101114152122Q125023345678101114152122R20003456781011141521226.5AcRe0112357101421234681115222.12 SAMPLES

Throughout the development and production cycles, Live Fire and/or the customer will requireseveral samples. Most DI customers have specific sample requirements that are publishedprior to the start of the project. The protocols and required samples for a DI program are listed

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in section 2.9 Overinspection 2. Live Fire may request samples at any given point throughoutthe life of the project. When a sample is requested, the supplier will be notified (usually viaemail) and given enough time to prepare the sample. Some samples may be required in theU.S., some may be required by Live Fire staff in Asia and some may be required by thecustomers’ buyer. Samples generally asked for by Live Fire are listed in this section.

2.12.1 Color Match – Complete or partially complete units, cartons, literature or samples of any

of these may be requested to verify that carton art, product color or literature matchestablished Pantone colors or color samples provided by Live Fire.

2.12.2 Hand Made – One or more hand made sample may be requested by Live Fire. This

sample is not usually expected to be perfect or off tool. It is generally requested early inthe development phase. Hand or off tool components may also be requested. This isusually to verify supplier’s understanding of the part’s stated purpose, design or color.

2.12.3 Off Tool – A completed unit or units may be requested by either Live Fire U.S. or Live

Fire Asia. This sample may or may not need to include cartons, graphics or literature.What is required will be specified when sample is requested.

2.12.4 First Article – An off tool sample that completely represents production units including

finished carton, literature and a sample of the warranty kits will always be requiredbefore the supplier is allowed to go into production. The sample may be sent to the LiveFire QA Manager in the U.S. or made available to the Live Fire project manager in Asia.Supplier will be notified as soon as possible in the project timeline, where the First Articlesample will need to go.

2.12.5 Buyer or Sales Sample – Often, Live Fire or the buyer will ask for a sample. At times

all that’s required is a representative sample and other times a production sample (offtool) is requested. Live Fire will notify the supplier if this is necessary, what type ofsample is needed and where to send it.

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ORGANIZATION AND RESPONSIBILITY

CHART 1 Live Fire Live Fire Quality Function Organization and Responsibility

2.13

INTERNATIONALLY SOURCED LIVE FIRE NEW PRODUCT QUALITY ASSURANCE PROCESSPROCESS / FUNCTIONRaw MaterialsSubcontractorsREQUIRED INPUTSSelection by primary supplierper Live Fire prints/specs.Selection by primary supplierACTIONApprovalSupplier approvalLF QA approvalACTION RESPONSIBILITYSupplier/Live Fire U.S.SupplierLF QA AsiaREQUIRED OUTPUTApproval or disapprovalApproval or disapprovalApproval or disapprovalApproval or disapproval by U.S. LF QA MgrAPPROVAL AUTHORITYLOCATIONLive FireSupplierLF QA AsiaChinaChinaChinaCritical Components - Selection by primary supplier, Approval by LF QANon certifiedCritical Components - CertifiedSelection by primary supplier, Approval by U.S. LF QA MgrConduct certification approval processLF QA U.S.LF QA U.S.U.S.SUPPLIER / LIVE FIRESupplier/Factory Inspection & SelectionAsia LF Project Mgr inspects site, assesses technical & QA capabilities, verifies capacity, forwards report to U.S. Signed copies of applicable VS agreements & QA and Sourcing managers with Quality Planning Manual. New or special recommendations. QA and Sourcing requirements or processes for product.managers approve or stipulates requirements needed to gain acceptance.QA reports from source, specifications & QA criteria from CB-LFCharbroil certification and approval to use componentApproved raw materials and componentsApproved parts / componentsCompleted units off packlineCompleted units off packlineCompleted units stored in warehouse or off packlineInspect parts in accordance with LF Quality Planning Manual.Inspect & test per LF Quality Planning ManualWorkstation inspections, manufactured part inspectionInspect & test per LF Quality Planning ManualInspect & test per LF Quality Planning ManualInspect & test per LF Quality Planning ManualLF QA AsiaSite inspection report, LF QA Asia China and recommendations for approval and/or AND Live Fire U.S.recommendations to gain approval.U.S.Incoming parts or componentsGas Train ComponentsIn Process inspectionPACKLINEFirst ArticleOffline test & InspectionOverinspection 1SupplierSupplierSupplierSupplierLF QA Asia or LF QA U.S.SupplierPart/Component approval or disapprovalReport to LF QA Mgr Approval or disapprovalStatus reports/log sheets & approval/disapprovalStatus reports/log sheets & approval/disapprovalSupplierSupplierSupplierSupplierChinaChinaChinaChinaChina or U.S.ChinaChinaF.A. Report on approval or C.A. on LF QA Asia or disapprovalLF QA U.S.Report on approval or C.A. on disapprovalReport on approval or C.A. on disapprovalSupplierLF QA AsiaRandom inspection & test per LF LF QA AsiaQuality Planning ManualOverinspection 2 (Customer requirements)Inspect factory examining technical & QA capability, facilities, human resource practices & policiesOutside lab Inspection & test per customer protocolsOutside lab Inspection & test per customer protocolsOutside lab Inspection & test per customer protocolsCustomerCustomerCustomerCustomerCUSTOMERFactory Pre-InspectionPre-production SampleProduction SampleLot InspectionCompleted customer documents listing supplier, location, processesCompleted factory assessment Completed units stored in warehouse or off packlineCompleted units stored in warehouse ready for container loadingApproval or disapprovalApproval or disapprovalApproval or disapprovalApproval or disapprovalCustomerCustomerCustomerCustomerChinaChinaChinaChinaCHART 2 Tollgates

INTERNATIONALLY SOURCED LIVE FIRE NEW PRODUCT TOLL GATESTOLL GATEREQUIRED INPUTSACTIONExamination of sample for adherance to engineering, quality and marketing specifications. May include non-critical component evaluation.ACTION RESPONSIBILITYREQUIRED OUTPUTAPPROVAL LOCATIONAUTHORITYInitial EvaluationPrototype sample(s)LF U.S. TeamReport back to supplier on LF U.S. Teamdeficiencies or improvements needed.U.S.SUPPLIER / LIVE FIRECritical Component ApprovalIf new critical component or component Complete evaluation of components and supplier, required samples will be specified supplier.per CB critical component approval protocolsLF QA U.S.Report on component or supplier on acceptance/rejection and deficiencies LF QA U.S.or improvements needed.Report on component acceptance or LF QA Asia or rejection and deficiencies or LF QA U.S.improvements needed.Component acceptance or rejection and deficiencies or improvements needed to part or processes.Approved First ArticleLF QA AsiaLF QA U.S. or LF QA AsiaU.S.First PieceIf required a significant number of off tool samples will be submitted to LF QA Asia staff Complete evaluation of components and LF QA Asia or LF for evaluation. In some cases this may be fabrication processQA U.S.handled by LF QA U.S.Off tool samples of every part submitted to LF Complete evaluation of components and QA Asia staff for evaluation.all processes.Verification of completion of all EP corrective actions. Off-tool samples of completed unit.Approved First ArticleCompleted units stored in warehouse or off packlineLF QA AsiaChina or U.S.Engineering Pilot RunChinaU.S. or ChinaChinaChinaFirst ArticleProduction Pilot RunLot InspectionsAssemble and inspect samples using IM LF QA U.S. (if time and following established LF QA permits) or LF QA guidelinesAsiaExamine packline operation for efficiency.Random inspection & test per LF Quality Planning ManualLF QA AsiaLF QA AsiaPackline improvements or approval to LF QA Asiaproduce.Approval or disapprovalLF QA AsiaPage 15 of31

CHART 3 Sample Size and Frequency

INTERNATIONALLY SOURCED LIVE FIRE NEW PRODUCT INSPECTION FREQUENCIESPROCESSINSPECTION LOCATIONSubcontractorSupplierSupplierSupplierSupplierSupplierINSPECTION FREQUENCYSuppliers discretionG-II, .65 AQLDesignated by Live Fire QAG-II, .65 AQLCOSMETIC= G-II, .65 AQL ASSEMBLY= S-4, .65 AQLCOSMETIC= G-II, .65 AQL ASSEMBLY= S-4, .65 AQLRaw MaterialsIQCPurchased Parts/ComponentsIn ProcessPacklineOverinspectionSUPPLIER / LIVE FIRE**NOTE** Different sampling frequencies may be used in place of those listed above if the situationwarrants it. Live Fire QA Manager will identify parts, processes or components that requireadditional or different sampling. Deviation requests from suppllier must be in writing.3.0 PRODUCT & PROCESS SPECIFICATIONS3.1

CATEGORICAL PROCESS QUALITY SPECIFICATIONS

3.1.1 Pre-wash (pretreatment) Minimum pretreatment Requirements (ref. SP006)

HRS(Hot RolledSteel)HRS P&O(Pickled &Oiled)CRS(ColdRolledSteel)CASTIRON

DegreaseHigh pH(soap)DegreaseHigh pH(soap)DegreaseHigh pH(soap)

Rinse(cleanwater)Rinse(cleanwater)Rinse(cleanwater)Wash(at source)

De-scale low

pH(Required)De-scale low

pH(Optional)De-scale low

pH(Optional)

Rinse

Neutralize

Rinse

Phosphate

Rinse

Rinse(If de-scale isused)Rinse(If de-scale isused)

NeutralizeRinsePhosphateRinse

Sandblast(at source)Sandblast(at painter)

• All oxidation or “scaling” must be removed.

• All parts must be completely dry prior to painting.

• Maximum time between pre-treatment and painting processes can be no more than

1 hour.• Live Fire suppliers are required to work with their paint suppliers and pre-treatment

chemical suppliers to optimize their systems.

• Settings recommended by the system or chemical suppliers may be used in place of

the settings listed above but must still satisfy ALL Live Fire requirements for

adhesion, rust protection, durability AND be approved in writing by Live Fire Qualityor Engineering.

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3.1.2 Coating Minimum Process Requirements (ref. SP006)

(general guidelines only. Product specific details if any, will take precedence)

Powder(600 F)

Max time Between wash& dry < 10 min Max timebetweenWash & dry< 10 minMax time

between wash& dry < 10 min

Drying Temp180 F minimum(after pre-treat)Drying Temp180 F minimum(after pre-treat)Drying Temp180 F minimum(after pre-treat)

Drying Time 20

Minutes(after pre-treat)Drying Time 20

Minutes(after pre-treat)

Electrostatic gunapplication,1.75 mils min.Electrostatic gunapplication,1.75 mils min.Electrostatic gun

or dipapplication

CuringTemp220 FCuringTemp200 FCuringTemp1200 F

Liquid(1000 F)

Porcelain

CuringTime18minutesCuringTime18minutesCuringTime20minutes

• Live Fire suppliers are required to work with their paint suppliers and pre-treatment

chemical suppliers to optimize their systems.• NO scratches.

• NO light paint where metal can show through.

• Coating thickness of powder coat or liquid paint can be no less than 1.75 mils thick

measured with an electronic thickness meter

• Uncoated steel surfaces are to be properly pretreated and phosphated per table

in 3.1.1

3.1.3 Plating (Copper)WASHElectro chemical baseplate (Electrophoresis)RINSEPrepare surface(rough up)ChemicalsealElectro chemicalbase plateRINSEOvenDryElectro chemicalCopper Plate (60 min)RINSEBlunt (chemicalseal)3.1.4 Anodize (Aluminum Pots)DegreaseRINSEAnodize (Acid)RINSE (Neutralize)Dry3.2 CATEGORICAL MATERIAL QUALITY SPECIFICATIONS

3.2.1 General

• ALL parts must meet specifications and dimensions listed on prints• ALL parts must mate easily with adjoining parts

• ALL screw / bolt holes must line up correctly with mating holes• ALL material thickness must be within tolerances listed on prints

• ALL plating thickness must be within tolerances listed on prints, including edges• ALL coating thickness must be within tolerances listed on prints

3.2.2 Porcelain Surfaces

• All porcelain coated surfaces must conform to specifications listed on prints• NO chips, scratches, cracks or dents• NO runs or drips in coating

• NO Boiling or gas bubbles showing through surface• NO Orange Peel

• NO tape or other foreign material under coating• All screw/bolt holes must be free of coating

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• Coating must be uniform thickness on entire part measured with an electronic

thickness meter• NO rust

• NO water or oil stains

• Must fit mating parts after coating• Must meet approved color samples

• Must meet or exceed acid resistance requirements

• Must be certified as acceptable for food contact (if applicable)• Lead and Cadmium content must be below FDA minimums

• Must withstand salt fog @ 5% concentration for 24 hours without chalking, fading

or loss of finish prior to First Article approval

• GB (Chinese) standards for rating corrosion are not recognized or approved by

Live Fire.

3.2.3 Paint

• All painted surfaces must conform to specifications listed on prints

• Must withstand salt fog @ 5% concentration for 24 hours without corrosion or

loss of finish prior to First Article approval

• GB (Chinese) standards for rating corrosion are not recognized or approved by

Live Fire.

• Must pass adhesion tests per ASTM D3359

• Must withstand burn tests per SP003 without bubbling, peeling or cracking.• Liquid paint must be rated to at least 1000 degrees F• Powder paint must be rated to at least 600 degrees F

• Liquid paint thickness 1.0 mils to 3.0 mils measured with an electronic thickness

meter

• Powder paint thickness 1.8 mils to 3.0 mils measured with an electronic

thickness meter

• NO chips, scratches, cracks or dents• NO runs or drips in coating

• NO boiling or gas bubbles showing through surface• NO Orange Peel

• NO tape or other foreign material under coating• All screw/bolt holes must be free of coating

• Coating must be uniform thickness on entire part• NO rust

• NO water or oil stains

• Must fit mating parts after coating• Must meet approved color samples

• Lead and Cadmium content must be below current FDA minimums > 600 ppm

3.2.4 Plating (Copper)

• All copper surfaces must conform to specifications listed on prints• NO stains of any kind on plated surfaces• NO rust

• Fingerprints, smears or smudges must be removed before packing

• Must withstand salt fog @ 5% concentration for 24 hours without chalking, fading

or loss of finish prior to First Article approval

• GB (Chinese) standards for rating corrosion are not recognized or approved by

Live Fire.

3.2.5 Steel (CRS & HRS)

• Gauge and steel type must match specifications listed on prints• NO rust

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3.2.6

3.2.7

3.2.8

3.2.9

• NO burrs allowed on any edge or flat surface• NO chips, scratches, cracks or dents

• All screw/bolt holes must be fully open with no burrs or blockage• NO die or tooling marks• NO water or oil stains

• All uncoated steel parts must be lightly coated with vegetable oilSteel (Cast)

• Must conform to specifications listed on prints• NO rust• NO burrs

• NO chips, scratches, cracks or dents

• All screw/bolt holes must be fully open with no burrs or blockage• NO die or tooling marks• NO water or oil stains

• All uncoated steel parts must be lightly coated with vegetable oil or

biodegradable wax

Stainless Steel

• Must conform to specifications listed on prints• NO rust

• NO burrs allowed on any edge or flat surface• NO water or oil stains

• Fingerprints, smears or smudges must be removed before packing• All screw/bolt holes must be fully open with no burrs or blockage

• Must withstand salt fog @ 5% concentration for 24 hours without chalking, fading

or loss of finish prior to First Article approval

• GB (Chinese) standards for rating corrosion are not recognized or approved by

Live Fire.

Copper

• All copper surfaces must conform to specifications listed on prints• NO burrs allowed on any edge or flat surface• NO discoloration allowed on any surface• NO water or oil stains

• Fingerprints, smears or smudges must be removed before packing• All screw/bolt holes must be fully open with no burrs or blockage

• GB (Chinese) standards for rating corrosion are not recognized or approved by

Live Fire.

Chrome

• Must conform to specifications listed on prints

• See CP 4203-SP for additional requirements and instructions• NO burrs allowed on any edge or flat surface• NO water or oil stains

• Fingerprints, smears or smudges must be removed before packing• NO rust

• NO burrs allowed on any edge or flat surface• NO chips, scratches, cracks or dents

• If used for anything that may come in contact with food, must be certified as safe

for food contact and contain no heavy metals (Lead & Cadmium)

• Must withstand salt fog @ 5% concentration for 48 hours without chalking, fading

or loss of finish prior to First Article approval

• GB (Chinese) standards for rating corrosion are not recognized or approved by

Live Fire.

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3.2.10 AnodizeRequired tests:

1. ABRAISION – Attach a cotton pad onto the bottom of test plate. Cut a 3M heavy

duty Scotch Brite Pad to 5/8” x 5/8” and attach to the bottom of the cotton pad withdouble sided adhesive tape. Attach a 1.5 kg load to the top of the moving plate.Attach the test fixture to the motor and set for 60 strokes per minute. Adjust cycle tostop after 1,000 strokes. With test piece in place, start test. While testing,

continuously blow air on piece to remove any particles from test surface. Examinepart after 1,000 strokes. If no failure occurs, repeat test until failure. Check pieceevery 100 strokes. Replace Scotch Brite Pad every 300 strokes.

2. COATING EFFECT – Apply one to two drops of pre-treatment solution on the test

specimen at 23 degrees C +/= 2 deg C for one minute. Rinse specimen and blowdry. Repeat this process with actual test solution. Examination of the specimenshould show no dye remaining in the test area.

SOLUTIONS:

Pre-treatment solution:

25ml/L (1.84g/cm3) Sulfuric Acid, 10 g/L Potassium Fluoride, or 25ml/L H2SiFe.

Test Solution:

2g Aluminum Blue 2LW dissolved in water, volume ratio of 1:1, pHvalue 5.0 +/- .05 @ 23 deg C +/- 2 deg C (use H2SO4 or NaOH toadjust pH). Or 10g Aluminum Red B3LW dissolved in water,

volume ratio 1:1 pH value 5.0 +/- .05 @ 23 deg C +/- 2 deg C (useH2SO4 or NaOH to adjust pH value).

NOTE: Use of test solution depends on color of test specimen. Thetest solution must be stored in a dark brown glass container out of

sunlight. Test solution cannot be used after 8 hours of exposure (out ofcontainer).

3. HEAT UP – Fill pot with approximately 2” of cooking oil (peanut oil is preferred but

vegetable oil is acceptable). Using a turkey fry stand, burner (obtain from customer ifnecessary), and suitable LP gas, place pot on stand and heat oil to 163 deg C.

Maintain oil temp for 2 hours. Remove from heat and allow to COMPLETELY cool toroom temperature. Clean and examine pot for discoloration.

NOTE: Discoloration caused by carbon deposited on pot from burner is

not considered to be a failure.

• Must conform to specifications listed on prints

• Color must be within limits defined by approved color sample

• Color, thickness, abrasion, coating effect and heat up tests to be conducted by

factory.

• Sample size for color testing and appearance – 100% of production• Sample size for thickness – 1 sample from each bar (half bath)

• Sample size for abrasion and coating effect – 1 sample per day during production• Samples size for heat up – 1 sample every 5,000 units produced• NO scratches• NO discoloration• NO visual defects

• Minimum anodize thickness at any point .025 mm

• NO base metal exposure after 1,000 strokes @ 1.5 kg load.• NO dye shall remain on surface after dye spot test• NO discoloration of sample after heat up test

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• All test results, reject rates and documentation are to be retained by anodizing

factory and available upon request by Live Fire personnel

3.2.11 Zinc

• Must conform to specifications listed on prints• NO oxidation allowed.

• NO rust allowed on Zinc plated parts.• NO Water or oil stains

• Must withstand salt fog @ 5% concentration for 24 hours without chalking, fading

or loss of finish prior to First Article approval

• GB (Chinese) standards for rating corrosion are not recognized or approved by

Live Fire.

3.2.12 Galvanized

• Must conform to specifications listed on prints• NO oxidation allowed.

• NO rust allowed on galvanized parts.• NO Water or oil stains

• Must withstand salt fog @ 5% concentration for 24 hours without chalking, fading

or loss of finish prior to First Article approval

• GB (Chinese) standards for rating corrosion are not recognized or approved by

Live Fire.

3.2.13 Wood

• Must conform to specifications listed on prints

• Moisture content must be below 10% prior to shipping using an approved

calibrated electronic moisture meter

• NO mold or mildew is to be present on any wood surface• NO dirt, dust, grit, trash ,etc. on any surface• All wood parts must match in color and tone• NO warping

• NO cracks, splits, splinters or chips• NO water or oil stains

• NO mechanical damage i.e. gouges, rough cut surfaces, etc.• Finger joints not allowed unless permission granted by Live Fire• Type of wood to be used must be authorized by Live Fire• NO knots allowed unless authorized by Live Fire

3.2.14 Bamboo

• Must conform to specifications listed on prints

• Moisture content must be below 10% prior to shipping using an approved

calibrated electronic moisture meter

• NO mold or mildew is to be present on any surface• All Bamboo parts must match in color and tone• NO warping

• NO cracks, splits, splinters or chips• NO water or oil stains

• NO mechanical damage i.e. gouges, rough cut surfaces, dents, etc.• Finger joints not allowed unless permission granted by Live Fire• Maximum number of horizontal laminations - 8

• Bamboo must be clear coated unless otherwise specified by Live Fire

• No de-lamination allowed. Run a thin blade along each lamination with moderate

to heavy pressure to test. Blade must not break through surface.

3.2.15 Aluminum

• Must conform to specifications listed on prints

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• UV stable equal to 3-5 years. Expose a section of the test piece to UV light for

96 hours. Cover remaining portions of test piece with material that will not allowlight to penetrate. No discoloration or fading.

• Must not show damage from weather, rain, hail, snow, etc. Immerse a section or

sample in normal tap water for 96 hours. Sample and bath are to be placedoutside for duration of test.• NO water or oil stains• NO cracks

• NO dents creases or holes (other than those required for mounting)• NO scratches visible through coating

• Any casting burrs must be removed or ground smooth• Colors and texture must match approved color samples

• Must withstand salt fog @ 5% concentration for 24 hours without chalking, fading

or loss of finish prior to First Article approval

• GB (Chinese) standards for rating corrosion are not recognized or approved by

Live Fire.

3.2.16 Welds

• Must conform to specifications listed on prints

• All perpendicular wire to wire weld joints must be full circumference welded (fig 1)• Fillet welds at all multiple wire termination joints (fig 2)

• Parallel wire to wire or wire to flat junctions must be welded top & bottom (fig 3a &

3b)

• • • • • • • • • • • Flat to flat junctions must be welded on both sides of joint (fig 3c)

Perpendicular wire to flat junctions must be welded on both sides of joint (fig 3d)Perpendicular flat to flat junctions must be welded on both sides of joint (fig 3e)All welds must be clean and ground smooth All welds must be fully intact.All burrs must be ground smooth.NO cracked or broken welds.

NO gaps or holes allowed along welded joints

Tack and spot welds must engage both mated surfaces, not sit on topNO excessive weld splatter (BB’s are weld splatter >.03125”)NO curling or overlap at weld seams

3.2.17 HVR

• ONLY pre-approved H/V/R components are to be used

• Pre-ship and random lot inspection to be completed per SP005

• Applicable CSA mandated combustion, burn, and ignition must be performed per

schedules listed in 2004 Cooker and 2004 Gas Fireplace Live Fire Quality Plans

3.2.18 Burners (cast & formed steel)

• Must conform to specifications listed on prints

• ONLY pre-approved Burners are to be used on Live Fire products• NO flame lifting in no wind and light wind ( < 10 mph)• Flame must be present above all ports• NO rust

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• Applicable CSA mandated combustion, burn, and ignition must be performed per

schedules listed in 2004 Cooker and 2004 Gas Fireplace Live Fire Quality Plans

3.2.19 Hardware

• Coating and material type must be as specified on prints• Threads must be free of excess coating

• Must be SAE unless otherwise specified by Live Fire• Must meet applicable torque standards

• Must be encased in blister pack before shipping

• Must withstand salt fog per ASTM B117-97a without chalking, fading or loss of

finish prior to First Article approval

• GB (Chinese) standards for rating corrosion are not recognized or approved by

Live Fire.

• All bolts and nuts used to assemble firebox to smoke chamber must be grade 5.

Other hardware that is required to be grade 5 will be specified on print.

• All hardware must withstand salt fog @ 5% concentration for 24 hours without

chalking, fading or loss of finish.

3.2.20 Temperature Gauges

• Text and graphics clear and sharp• Accuracy +/- 10 deg F (full scale)

• Heat Resistant glass must not crack when heated to cooking temperature zones.

Place gauge in oil or in an oven and raise temp to 80% of full scale. Removefrom heat and spray gauge face with water. Glass must not crack or chip.• Must pass all tests listed in Live Fire Test Method: CBT 700-SP

3.2.21 Cooking Grates

• Must conform to specifications listed on prints

• If porcelain, must conform to CGP-0008, Non-Stick/Porcelain Coated

Accessories

• If Chrome Plated, must conform to CP 4203-SP Specifying and testing Chrome

Plating

• If porcelain, Lead and Cadmium content must be below FDA minimums (> 600

ppm)

• All uncoated grates must be lightly coated with vegetable oil or biodegradable

wax.

3.2.22 Glass Lids

• Must conform to specifications listed on prints• Must meet criteria specified in ASTM C149-86

3.2.23 Covers

• Must conform to specifications listed on prints or marketing specification• Must meet specified criteria listed in workmanship standard CGP-0004

3.2.24 Electrical or Electronic Parts

• Wire casing must be intact, no abrasions, cuts or bare wire

• NO scratches, worn areas, cracks or blemishes on porcelain insulators• Spark wire must be intact and shaped properly

• Incoming inspection ANSI/ASQC Z1.4-1993 Inspection Level G-II, AQL .65

• Wires must attach to components correctly with light to moderate pressure (to be

specified on print)

• Wire type should be per print

• All seals must be intact, in good condition and properly seated• Component screws must be tight, not stripped or backed out• No scratches, worn areas or blemishes on plastic parts

• Units with transmitters and receivers - must transmit and receive from 10' straight

out from receiver and 3' side to side @ 10' (100%) (see diagram)

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• Any battery doors must be moderately easy to open and firmly latch in place

when closed

• Light diodes must be in proper position, no cracks, chips or scratches• Receiver window must be intact, no scratches, chips, or abrasions

• Batteries are not to be installed without written permission from Live Fire

3.2.25 Refractory Components & Material

• Refractory materials must withstand 1500 F without breaking down or melting• Refractory material must not contain any harmful or non FDA, EPA or OSHA

approved substances

• Refractory components must not crack during or after multiple uses

• All moisture must be pre-baked out of material prior to finishing or packaging to

prevent moisture expansion causing material to crumble, flake off or break off• Refractory components must be packed so that breakage during normal shipping

operations cannot occur

3.2.26 Carton

• Graphics files will be provided by Live Fire. Final carton graphics must be

approved by Live Fire before production

• Graphics must be clear and legible with correct spelling, grammar and color

tones

• Must protect product during shipping (ISTA transit are required) Live Fire will

specify applicable ISTA test(s)

3.2.27 Innerpack

• Must protect product during shipping (ISTA transit are required)

• Any clear polypropylene, plastic bags, etc material used must have applicable

choke and child safety warnings

3.2.28 POP

• Must match approved color and artwork sample. Graphics files will be provided

by Live Fire

• Graphics must be clear and legible

• Adhesive sufficient to hold POP in place while allowing it to be removed without

leaving any residue

• POP shall adhere to surface without peeling after being in oven at 160 F for 48

hours.

3.2.29 Instruction Manual

• Assembly instructions will be provided by Live Fire. Instructions must be clear

and legible

• Live Fire maintains master copy. NO changes can be made by supplier

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3.3

TOLERANCE

In cases where conflicting dimensions or tolerances are discovered, there is an order of rankingthat is used to determine what has precedence. If this condition is discovered, Live Fire QA andEngineering are to be notified immediately.

3.3.1 Order of Hierarchy – Dimensions and tolerances listed on prints ordinarily supercede

anything listed in any other document. The two exceptions are when there are

conflicting dimensions or specifications listed in external standards (government, ASTM,ANSI, CSA, etc) or Charbroil company standards. Most external and internal standardsdo not contain dimensions or tolerances. In the rare case where they do, the externalstandard followed by the internal company standard and customer standard (if

applicable) has precedence. The following is a list of documents ranked by authority.

1. External standard – U.S. Government, ASTM, ANSI, FDA, CSA, UL, BS, etc.2. Internal Charbroil standards.

3. Customer standard – Specified by the Live Fire customer.4. Live Fire Engineering models, prints and drawings.

5. Live Fire Quality Assurance Standards – Written or adopted by the quality

assurance group.

6. Product or process specific specifications- Developed for a particular

manufacturing or sourcing process or product by Live Fire.

In most cases, these all coincide with each other. Live Fire Engineering models andprints have incorporated external and internal specs as part of the model package.

Unless otherwise specified, tolerances and tolerance charts can be found on all Live Fireprints and drawings. There are no deviations to these tolerances allowed withoutprint/drawing revision approved and published by Live Fire Engineering.

Live Fire QA will use these dimensions and tolerances for all product and processapprovals.

The supplier is free to convert standard English measurements to metric for ease of usewithin his process. If dimensions are converted, they must match standard Englishdimensions exactly. Live Fire models and prints are the ONLY official document ofrecord for all dimensions and tolerances.If a model dimension or tolerance is unachievable by the supplier, a full explanation anddetailed proposed change must be submitted in writing to Live Fire Engineering andQuality Assurance requesting approval for change.

If a procedural deviation (external, company, customer standard, QA standard orprocess /product specific standard) is requested, supplier must submit proposal andreason for requesting change in writing to Live Fire QA.

3.3.2 3.3.3 3.3.4

3.3.5 3.3.6

3.4

RUST (Comment)

Since most Live Fire products are made of materials susceptible to corrosion, extra care mustbe taken to minimize the risk of this reaction. The pre-treatment processes and coatingsspecified in this document are based on years of experience and knowledge of how best tominimize the opportunities for rust generation. No deviations to these practices can be

tolerated. To further help prevent rust, all uncoated steel parts are to be covered with a lightlayer of vegetable oil.

The NO RUST ALLOWED specification must be adhered to without exception or deviation.

Page 25 of31

4.0 TESTING, INTERNAL4.1

Procedure/Standards – Supplier must possess, understand and follow all established

procedures and standards specified by Live Fire. Established industry best practice protocolsare to be adhered to at all times. Lab and test equipment is to be maintained in good workingorder at all times.

Measurement Standards/Techniques – Established practices and techniques are to be

followed at all times. All gauges are to be calibrated on regular intervals as specified by ANSI.Required Tests – Depending on the product, certain tests will be conducted by the supplier.Live Fire will identify the required tests for each product. They may include but are not limitedto:

• Adhesion test ASTM D3359-95a• Burn Test SP003

• Salt Fog Test ASTM B117

• Combustion, Burner Efficiency & Operating Characteristics listed in ANSI Z21.89-2002

• Combustion, Burner Efficiency & Operating Characteristics listed in CSA 4.96 • ASTM C149-86 (2000) Thermal Shock Resistance of Glass Containers• Temperature Gauge Testing as listed in CBT 700-SP• Grill Cover Testing listed in CGP-0004• Porcelain coating listed in CGP-0008• UL 1439 Sharp Edges• ISTA 1A, 1B, 2A, 2C

Other tests may be required by Live Fire. If so, supplier will be notified prior to project start.Live Fire will also require samples from time to time to audit particular processes orcomponents. These may include temperature gauges, gas regulators, burners, valves,porcelain or chrome components or completed units.

4.2

4.3

5.0 TESTING, EXTERNAL5.1

Product Testing – Depending on Live Fire customer requirements, there may be tests orinspections required that would be carried out on behalf of the customer at an independentlaboratory. Live Fire will notify supplier if this is a requirement.

Transit Testing – Transit testing is required on all Live Fire products whether the customerrequires it or not. The supplier is responsible for ensuring that the pack is adequate for survivalof transit testing. ISTA protocols are used for transit testing. The test used depends on the sizeand weight of the final package. Some customers use squeeze lift clamp trucks in theirwarehouses. Additional testing may be required to ensure the package is strong enough towithstand this kind of loading without damage to the product If this is required, Live Fire willprovide test method.

Material Testing – There are certain materials used on some Live Fire products that are

required to be tested or certified before they can be used. Examples of required documents orcertifications include but are not limited to: MSDS (Material Safety Data Sheets), certification ofheavy metal content (lead & cadmium), Porcelain acid resistance, burn test reports (paint),temperature gauge testing reports, salt fog test reports, etc. Live Fire will notify supplier ofrequired material testing.

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5.2

5.3

5.4

Regulatory Compliance Testing – Some products are required to be certified by a designatedagency to ensure it meets federal regulations or guidelines for safe handling or operation. Thecertification of these units is the responsibility of Live Fire. Once certified, Live Fire will

distribute a paper copy of the certification file to the supplier. This file must be on site at thefactory. Live Fire will also provide the supplier with instructions or examples of certificationrequired markings, labels, etc.

Customer Specified Testing – This will include everything listed in section 3.3 except forcertain items listed in 3.3.9 which are only required by Live Fire. Customer testing will beconducted at one of several established testing labs in Asia or the U.S. MTL, STR, Intertek,SGS and CTL are a few.

Customer Factory Audit/Process Inspection – Some of Live Fire’s customers perform

independent factory audits and process inspections. Typically this is only done when productwill be shipped direct from the factory to the customer (DI). The factory audits generally consistof inspections of personnel policy, health safety and welfare, records facilities, etc. The processinspections consist of discovering evidence of good quality assurance methods and practice,material tracking, process capability and consistency, etc. Live Fire will notify supplier ifcustomer inspections will be required.

5.5

5.6

6.0 6.0

SEGREGATIONNonconformance – The supplier is required to have an established procedure and method foridentifying, handling and segregating nonconforming parts and components. There should beprotocols for incoming parts/components, work in process and finished goods. The supplier isnot required to report to Live Fire on specific nonconforming issues unless they are designatedcritical components.

Corrective Action – The supplier should have in place a system where quick and concise

corrective actions are developed, implemented and tracked if nonconforming parts are detectedby the customer, Live Fire or the supplier. Live Fire and the customer, will require CorrectiveAction Reports (CAR’s) that list the nonconformance in detail, the reason it occurred, what isbeing done to correct the problem, what is being done with the defective parts (either in thefactory or in the field) and what will be done to prevent it from happening again. Suppliers are100%responsible for the organization, operation and expense of any recall or rework caused bythem or their subcontractors.6.1

7.0 7.0

TRACEABILITYProtocol – Charbroil requires that all it’s products are traceable through a system of lot

numbers and serial numbers. All Live Fire products are traceable under the Sourced ProductsComponent ID &Traceability Protocol CP4601-SP. Along with that protocol, there are two workinstructions (PWI 003-SP & PWI 004-SP) the supplier must have, understand and follow withoutexception. All components and part production from all sources must be tied to the product lotnumbers. Violation of the protocol is subject to supplier disapproval.

Record Keeping – The traceability protocol and the work instructions detail the documents

required, their format and file storage locations. The spreadsheet that the supplier is required touse will be provided by Live Fire.

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7.1

8.0 8.1

DOCUMENTATIONVS1-SP - All first tier suppliers are required to obtain, read, understand and sign a copy of VS1-SP before any awarded project can begin. It is not necessary to sign a new copy for each newproject.

Live Fire Quality Planning Handbook - All first tier suppliers are required to obtain, read,understand and sign a copy of the Live Fire Quality Planning Handbook before any awardedproject can begin. It is not necessary to sign a new copy for each new project.

Part/Material Prints, Specifications – Live Fire will provide ALL manufactured part prints andspecifications to the first tier supplier. The supplier is allowed to modify prints and drawings formanufacturing or language purposes but the master copy retained by Live Fire will ALWAYS bethe document of record. Any request for change must be submitted in writing and approved byLive Fire engineering.

Live Fire Inspection Reports – Live Fire inspection reports are normally in the form of TripReports or Site Visit Reports. This is when a member of the Live Fire staff visits the supplier’sfactory or subcontractor and makes his inspection. He will generate and distribute a trip reportto Live Fire staff and the supplier that contains items or discrepancies that need to be corrected.Customer Inspection Reports – in most cases, customer reports will be issued to the supplier.The supplier must retain a copy and immediately forward a copy to Live Fire QA Manager,Sourcing Manager and Project Manager in Asia.

Weekly Quality Reports – All first tier suppliers are required to publish a weekly quality reportfor each model that is currently in production. This report should contain line items for dailypackline production, # of samples inspected, # of defective units or defects found, disposition,immediate corrective action and preventative measures. This report is to be sent to the LiveFire QA Manager (in English) and the Asia Project Manager by Tuesday of the following week.Certifications – CSA certifications (LP gas products only) must be filed at the factory or packlocation. Certain customers require this and will ask for the certification during their Factorytechnical assessments or during lot inspections. Live Fire will provide a copy of the Certificationto each factory that is producing LP gas products. Other certifications such as heavy metalcontent, transit test results, product test reports, MSDS, chrome, porcelain chemistry and sub-contractor inspection reports are to be sent to Live Fire as soon as they are available. All are tobe completed and published prior to EP. Live Fire QA Manager will publish any additionalfrequency requirements for each of these tests prior to EP. Daily inspection reports, HVR,combustion, temperature gauge, burn test and adhesion tests are to be retained by the factoryand available upon request by Live Fire.