Quality Name Plate AS9100 Quality System


QNP AS9100 Main Index

 

 


Control of Nonconforming Product

Control of Nonconforming Product: OP-830-01 Revision D

Effective Date:1/3/2014
Owner Approval by Brian Darby, on 1/2/2014
Management Approval by Craig O. Garneau, President, on 1/2/2014

Printed copies of this document are for information purposes only and are uncontrolled. Printed copies are not valid after the date of printing. This document was printed on

  1. PURPOSE

    To provide a consistent procedure for the identification, documentation, isolation, control, and disposition of all nonconforming product.




  2. RESPONSIBILITY

    The table below identifies the people and their responsibility relating to this procedure:

     

    Person

    Responsibility

    Receiving Personnel

    Verify at receiving inspection that material provided by suppliers is in accordance with customer and/or Quality Name Plate specifications.

    Arrange to inform suppliers when nonconforming product is received.

    Shipping Personnel
    (Inspectors & Packagers)

    Perform the Final Inspection Procedure to verify that production at QNP conforms to the quality plan as generated from the customer blueprint, purchase order, and other quality standards.

    Production Personnel

    Maintain production standards.

    Perform Production Inspections as required.

    Notify supervisor of suspected nonconforming product.

    Department Supervisors/Lead Inspector

    Quality Assurance Manager

    President

    Vice President

    Identifies standards in order to define conforming product and nonconforming product.

    Isolates all nonconforming product in a designated area when required.

    Provides for any "accepted", "hold-do not use", "rework", or "scrap" dispositions.

    Serve as members of the Material Review Board (MRB)




  3. APPLICABLE FORMS OR REFERENCES

    The table below identifies the number and the title of the forms and references that are applicable to this procedure;

    Form/Reference Number

    Title

    AS9100

    Quality Management Systems - Requirements for Aviation, Space and Defense Organizations

    OP-743-01

    Verification of Purchased Product

    OP-754-01 Control of Customer Property

    OP-824-01

    Production Inspection

    OP-830-02 Customer Complaints
    FM-710-01 Shop Order/Quality Plan

    FM-743-01

    Material Control Label

    FM-824-01

    Production Inspection Report

    FM-830-01

    Hold Tag

    FM-830-02

    Scrap Tag

    FM-830-03

    Repairable or Rework Tag

    FM-830-05

    Escape Form




  4. POLICIES

    1. Nonconforming product is defined as material that does not meet
      • Product Requirements
      • Customer specifications.
      • Other specified standards set by Quality Name Plate, and
      • Cannot be used in production.

    2. Nonconforming product encompasses;
    3. Segregated areas for nonconforming product are located throughout the company and identified with signs, floor tape, or other appropriate means. Nonconforming product areas may be used to store nonconforming product, suspected nonconforming product, or product that cannot be processed further without Management or MRB intervention.

    4. "Hold", "Scrap" and "Rework" markers are available in the nonconforming product areas. Product that can be dispositioned quickly or is readily identifiable may be identified with a generic "Hold", "Scrap," or "Rework" marker, provided that MRB dispositions are recorded on the Shop Order or Production Inspection Report, FM-824-01. Product that cannot be dispositioned quickly, or is not readily traceable to a shop order number or some other positive identification should be affixed with a completed Hold Tag FM-830-01, Scrap Tag FM-830-02, or Repair/Rework Tag FM-830-03.

    5. When it is not practical to move product to a designated nonconforming product area, the product may be conspicuously marked with an appropriate tag or marker to prevent unintended use.

    6. Nonconforming product once identified shall not be used in production without the approval of the MRB (Material Review Board). Suspected nonconforming product, or product awaiting MRB intervention should not be removed from a designated nonconforming product area without MRB approval.

    7. Members of the Material Review Board have the experience, knowledge and training necessary to make the appropriate decisions regarding the disposition of non-conforming material. The purpose of the Material Review Board (MRB) is to:
      • Review all nonconforming product exposed during:
        • Receiving Inspection
        • Production Inspections
        • Final Inspection
      • Decide on the disposition of nonconforming product.

    8. The qualifications, scope of approval, and authority by which employees are members of the Material Review Board are defined and documented within their training records. Typically, the Material Review Board shall consist of one or more of the following personnel when required:
      • President
      • Vice President
      • Quality Assurance Manager
      • Department Supervisors/Lead Inspector
      • Any personnel judged to have an impact on a solution towards the disposition of nonconforming product.

    9. When the Material Review Board sends an order into rerun, the results shall be recorded on the Escape Form, FM-830-05. Nonconformances detected within the company shall be coded as an "Internal Nonconformance". Nonconformances detected by a customer shall be coded as a "Customer Complaint." The Escape Form, FM-830-05 shall document the actions taken to eliminate the detected nonconformity, as well as the actions taken to contain the effect of the nonconformity on other processes or product.

    10. Repairable or reworkable is defined as nonconforming material that is physically segregated from conforming material and can be reprocessed to conform to specification. Corrected nonconforming product is subject to re-verification to demonstrate conformity to requirements.

    11. Scrap is defined as material that is nonconforming and has been processed beyond a point of reclaim. Product dispositioned for scrap is conspicuously, permanently marked or positively controlled to prevent unintended use.

    12. Product intended for Aerospace or Tier 1 customers that is dispositioned for scrap shall be rendered unusable per the requirements of ASQR-01.

    13. Product intended for Commercial, Tier 2, or Tier 3 customers that is dispositioned for scrap may be discarded in a controlled scrap barrel.

    14. Hold - "Do Not Use" is defined as material that is potentially nonconforming and waiting for disposition by the Material Review Board.

    15. All employees at Quality Name Plate are responsible for quality, and have the authority to initiate action to contain nonconformities.

    16. Any output that is produced and passed on to the next production step is assumed to be in compliance to specification.

    17. The results of an MRB disposition may be recorded on the Shop Order FM-710-01, Production Inspection Report FM-824-01, or Escape Form FM-830-05. A Hold, Scrap or Rework tag does not need to be retained as a quality record unless is it the sole source of documentation. A Hold, Scrap or Rework tag retained as a quality record should be maintained with the Shop Order.

    18. Nonconforming customer supplied property is disposed in accordance with OP-754-01 Control of Customer Property.

    19. Nonconforming incoming raw material is disposed in accordance with OP-743-01 Verification of Purchased Product.

    20. Nonconforming product detected and returned by a customer is disposed in accordance with OP-830-02 Customer Complaints.

    21. If a nonconformance is discover after product has shipped, the customer is to be notified without undue delay (same business day if possible) with a clear description of the non-conformity and the information necessary to identify any affected parts. The Escape Form, FM-830-05 shall be used to document the actions taken to alert the customer and control the nonconforming product. When appropriate, affected suppliers, distributors, other internal departments, or regulatory authorities shall be notified in a timely manner as well.

    22. When a nonconformity results in a departure from contract requirements, QNP does not disposition nonconforming product as "use-as-is" unless specifically authorized by the customer. Records of the authorization shall be maintained.

     

     


  5. PROCEDURE

    Nonconforming product at Quality Name Plate is controlled using the following individual procedures:

    • 5.1 In-Process/Final Inspection Nonconforming Product
    • 5.2 Repairable of Rework
    • 5.3 Rejected or Scrap
    • 5.4 Rerun an Order

    5.1 In-process Inspection/Final Inspection nonconforming product

    Use the steps in the table below to control non-conforming product identified during in-process inspection.

     

    Step

     

    Action

     

    Person(s) Responsible

     1

    Nonconforming product identified during in-process inspection or final inspection. Ref: OP-824-01 Production Inspections

     Production Personnel

     2

    Production is stopped and department supervisor/lead inspector is notified.

     Production Personnel

     3

    Nonconforming product reviewed for disposition.

     Department Supervisor/Lead Inspector

     4

    Identified nonconforming product marked with a Hold Tag, FM-830-01.

     Department Supervisor/Lead Inspector

     5

    Material Review Board member notified in order to review nonconforming product samples and applicable reports.

     Department Supervisor/Lead Inspector and/or Material Review Board

     6

     Decide disposition of nonconforming material.

    Department Supervisor/Lead Inspector and/or Material Review Board

     7

    Record results of disposition Hold Tag, FM-830-01. If appropriate, record the nature of the nonconformance and any subsequent actions taken on an Escape Form, FM-830-05.

    Department Supervisor/Lead Inspector and/or Material Review Board

    8  Dispose of material.

    Department Supervisor and/or Material Review Board

     

    5.2 Repairable or rework

    Use the steps in the table below to control non-conforming product identified as rework.

    Step

    Action

     Person(s) Responsible

     1.

    Nonconforming product reviewed and designated as repairable or reworkable.

    Department Supervisor and/or Material Review Board

     2.

    Repairable or Rework tag, FM-830-03 affixed to identified rework material.

    Department Supervisor and/or Material Review Board

     3.

    Product is reworked.

    Production Personnel

     4.

    Reworked product inspected to ensure conformity to the original requirements.

    Department Supervisor and/or Material Review Board

    5.

    FM-830-03 is forwarded to the quality assurance department to be maintained as a quality record.

    Department Supervisor and/or Material Review Board

     5.3 Rejected or scrap

    Use the steps in the table below to control non-conforming product identified as Rejected or scrap.

     Step

     Action

    Person(s) Responsible

     1.

    Nonconforming product reviewed and designated as as rejected or scrap.

    Department Supervisor and/or Material Review Board

    2.

    Scrap Tag, FM-830-02, is attached to material. If appropriate, nonconforming material may be disposed of immediately without the issue of a scrap tag.

    Department Supervisor and/or Material Review Board

    3.

    Scrap material is placed in designated area to prevent unintended use or delivery. Permanently mark material as "scrap" if appropriate.

    Department Supervisor and/or Material Review Board

     4.

    Scrap material is disposed of properly.

    Department Supervisor and/or Material Review Board

    5.

    Proceed to 5.4 Rerun an order

    Department Supervisor and/or Material Review Board



    5.4 Rerun an order

    Use the steps in the table below to rerun an order.

     Step

     Action

    Person(s) Responsible

     1.

    Order must be rerun due to nonconformance.

    Department Supervisor and/or Material Review Board

    2.

    Documents/Information of the nonconformance and disposition of product is forwarded to the quality assurance team.

    Department Supervisor and/or Material Review Board

    3.

    An Escape Form, FM-830-05, is generated.

    Quality assurance team

     4.

    On shop order, FM-710-01;

    • Staple a red Rerun tag to the to top
    • Note if the order is to be rerun for the complete or a partial quantity
    • Describe the nature of the nonconformance on the top flap
    • Amend the listed processes as necessary to correct the immediate cause of the nonconformance
    • Assign an appropriate ship date
    • Initial and date

    Quality assurance team

    5.

    Order is returned to production.

    Quality assurance team



  6. RECORDS/OBJECTIVE EVIDENCE

    The retention duration for records referenced in this procedure are available on-line in the FM-423-01 Master Document List with Revision History.
    Records are maintained in accordance with OP-424-01 Control of Quality Records.


  7. REVISION HISTORY

    Revision, approved date, effective date, and a document change summary for this document is located on-line in the FM-423-01 Master Document List with Revision History.