ML19274D229
| ML19274D229 | |
| Person / Time | |
|---|---|
| Site: | 07100258 |
| Issue date: | 12/27/1978 |
| From: | U.S. ECOLOGY, INC. (FORMERLY NUCLEAR ENGINEERING |
| To: | |
| Shared Package | |
| ML19274D228 | List: |
| References | |
| NECO-01-100, NECO-1-100, NUDOCS 7901160320 | |
| Download: ML19274D229 (33) | |
Text
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h QUALITY ASSURANCE MANUAL i
NUCLEAR ENGINEERING COMPANY, INC.
P. O. B0X 7246 LOUISVILLE, KENTUCKY 40207 j
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7901160390
,.7 QUALITY ASSURANCE MANUAL NUCLEAR ENGINEERING COMPANY, INC.
P. O. BOX 7246 LOUISVILLE, KENTUCKY 40207 COPYRIGHT 1978 7
NECO 01-100
- p. a 12/27/78 Rev.
~0-NUCLEAR ENGINEERING COMPANY, INC.
QUALITY ASSURANCE MANUAL INDEX I.
GENERAL Title, Index, and Approval NECO 01-100 Page a Record of Revision b
Statement of Policy c
Organization Chart d
Introduction and Matrix e
II.
QUALITY ASSURANCE SYSTEM Quality Assurance Manual NECO 01-101 Order Analysis, Planning and Design Control NECO 01-102 Document Control NECO 01-103 Procurement Control NECO '01-104 Process Control NECO 01-105 Inspection and Test Control NECO 01-106 Calibration of Measuring and Test Equipment NECO 01.107 Nonconformance and Corrective Action NECO 01-108 Quality Assurance Records NECO 01-109 Audits NECO 01-110 7-
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Approved:
Vice President CONTROLLED:
UNCONTROLLED:
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NECO nl-100
- p. c 12/27/78 Rev. STATEMENT OF POLICY It is the policy of Nuclear Engineering Company, Inc. to provide services and products of superior quality.
This Quality Assurance Manual is designed to provide that systems, procedures, and controls are in effect and implemented to satisfy applicable codes, specifi-cations, and requirements.
The Vice President is responsible for establishing NECO quality re-lated policy, and for the implementation and administration of this OA Manual through the Quality Assurance Section of the manufacturing subsidiary and the Chief Engineer.
Active participation of all other departments is mandatory.
The Chief Engineer and the Quality Assurance Manager of the manu-facturing subsidiary are directly responsible for and have the authority to prepare, maintain, update and audit compliance to these requirements.
They shal) halt operations when the continuing operations will create nonconforming material or when operations are not being implemented in accordance with the requirements of this QA Manual.
The successful operation of this program requires complete communica-tion and full cooperation of all personnel.
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NECO 01-100
- p. e 12/27/78 Rev.,
INTRODUCTION Nuclear Engineering Company, Inc. is a service und manufacturing company where quality assurance is easily maintained through direct management and control.
The basic management philosophy at NECO is that nothing shall be allowed to compromise product quality or com-pliance with required specifications, procedures, and drawings.
The quality of NECO's work is controlled and assured by the Quality Assurance Program.
The Quality Assurance Manual (QA Manual) outlines the program and is further defined by supplemental procedures.
The purpose of the QA Manual is to provide a working document for all departments at all facilities describing responsibilities, procedures, systems, and controls provided by NECO to meet the quality assurance requirements.
~
In addition, it is the intent of the program to meet the relevant requirements of ASME Section III, NA-4000; 10 CFR 50 App. B and ANSI N45.2 at the manufacturing facility and 10 CFR 71 App. E for the service facilities.
It is the responsibility of the manager of each department involved with the product line to follow the requirements of this QA Manual and to inform and train the personnel in the department in the uses of these procedures and systems, and to review the work of the depart-ment to assure compliance with all requirements.
9
NECO 01-100 p.
f 12/27/78 Rev. QUALITY ASSURANCE PROGRAM MATRIX NECO Quality Assurance frogram Appendix E Procedure No.
Section/
Criterion Pr'ogram Requirement Which Applies Paragraph II Q. A. Program NECO 01-100 Pg. e I
Organization NECO 01-100 Pg. d III Design Control NECO 01-102 Para. 5.0 IV Procurement Document Control NECO 01-104 Para. 3.0 V
Instructions, Procedures and NECO 01-103 Drawings NECO 01-102 VI Document Control NECO 01-103 VII Ccatrol of Purchased Material, Equipment and Services NECO 01-104 VIII Identification & Control of Material, Parts and Components NECO 01-105 Para.
2.0",
3.0, 4.0 IX Control of Special Processes NECO 01-105 Para. 6.0 X
Inspection NECO 01-106 Para. 2.0 XI Test Control NECO 01-106 Para. 4.0 XII Control of Measuring and Test Equipment NECO 01-107 XIII Handling, Storage and Shipping NECO 01-105 Para. 5.0 XIV Inspection, Test and Operating Status NECO 01-106 XV Nonconforming Items NECO 01-108 Para. 1.0-6.0 XVI Correcting Action NECO 01-108 Para. 7.0 XVII Q. A. Records NECO 01-109 XVIII Audits NECO 01-110 o
NECO 01-101 12/27/78 Rev..
QUALITY ASSURANCE MANUAL 1.0 PURPOSE 1.1 It is the purpose of this section to define the content and the responsibility for the preparation and control of the QA Manual.
2.0 CONTENT 2.1 This OA Manual shall constitute a written description of the Quality Assurance Program maintained by NECO for producing those items referenced in the Introduction.
The QA Manual shall contain sufficient detail and exhibits to be a working document for all departments.
3.0 RESPONSIBILITY 3.1 The Chief Engineer (CE) shall be responsible for preparation and maintenance of this QA Manual and for review and approval prior to submission for Management approval.
4.0 DISTRIBUTION 4.1 Numbered Controlled copies of the QA Manual shall be distrib-uted to all Management and Supervisory personnel who are in-volved in its implementation and other authorized personnel approved by Management.
4.2 Uncontrolled copies may be distributed to other persons only upon approval of the Vice President.
Such copies will not be updated.
5.0 REVISIONS 5.1 The QA Manual will be revised when significant changes occur in the quality system such as code requirements.
r
NECO 01-101 12/27/78 Rev..
5.2 The contents of the QA Manual shall be reviewed annually, or more frequently if required for possible updating.
5.3 Changes shall be reviewed and approved by the Vice President and the Chief Engineer.
6.0 RECORDS 6.1 The CE or a designee shall maintain a file of the individual to whom each controlled copy is furnished.
The record shall include:
name, copy number, revision number and record of revisions issued.
6.1.1 A record of Revision page shall be prepared for each issue of a revision.
6.2 A card file shall be maintained of the persons to whom uncontrolled copies are issued.
E.3 Addenda may be made to the QA Manual and shall be issued only to those personnel who are affected by the addenda.
6.3.1 Issuance of addendas shall be made and recorded as are revisions as previously described.
NECO 01-102 12/27/78 Rev..
ORDER ANALYSIS AND DESIGN CONTROL 1.0 PURPOSE 1.1 The purpose of this section is to establish the responsibility of Radiological Control and Safety, Quality Assurance and the Engineering departments to translate customer orders, specifi-cations, codes and other referenced documents into requirements for materials, processing, testing, inspection, work orders and documentation before the start of formal production.
2.0 CUSTOMER PURCHASE ORDER 2.1 The customer issues inquiries or bids which generates a pro-posal from NECO.
A firm customer order is handled as follows:
2.1.1 NECO Customer Orders for services shall be received by Sales.
The order and referenced documents (if applicable) is forwarded to Operations and Radiological Control and Safety.
2.1.2 PPI Customer Orders shall be handled in accordance with the PPI Quality Assurance Manual.
NECO service facilities shall be considered customers by PPI.
3.0 ORDER ANALYSIS 3.1 The customer order and attachments shall include the information required to pescess the order.
3.2 Analysis of customer orders received by PPI shall be conducted in accordance with the PPI QA Manual.
4.0 ORDER ANALYSIS REVIEW 4.1 Order Review Conference
NECO 01-102 12/27/78 Rev.
-G-4.1.1 A Pre-Job Conference may be held to review the contractual requirements in detail, obtain recommendations and define problem areas.
5.0 DESIG'N CONTROL 5.1 Designs are developed to meet internal requirements and to meet customer specifications on customer design and build items.
5.1.1 Designs are documented on drawings and specifications which becomo either part of NECO's standard design or part of a project design file.
5.2 Design document verification on individual drawings and draft sketches are confinmed by checkers who assure detail drafting practices were met, numbers and dimensions are correct and other technical details are acceptable.
Engineering verifies these documents to assure they correctly reflect the approved design.
Customer approvals are also obtained as required by contract on drawings, calculations and specifications.
5.3 Design activities shall be reviewed and approved by Quality Control to ensure product quality requirements are correct.
5.4 Approved drawings and specifications are released by Engineering for subsequent use in procurement and fabrication after customer approval if required.
5.5 If design changes and revisions are required, they go through the same cycles as the original and require the same approvals.
When the change has been approved, it is released to the same groups that received the original issue.
NECO 01-103 12/27/78 Rev. 4 l
L DOCUMENT CONTROL 6
1.0 PURPOSE To define responsibilities and control for preparation, distribution and control of records of the following documents:
Customer order, drawings and specifications Drawings and sketches Specifications and procedures 2.0 CUSTOMER DOCUMENTS 2.1 Customer furnished drawings and specifications will be received, reviewed and used according to Section NECO 01-102.
2.2 Marketing and Sales shall be responsible for maintenance of original and changes to the Customer Purchase Order and dis-tribution of the Customer Order and changes to appropriate personnel.
2.3 Drawings shall be retained in Engineering and/or other files as appropriate.
Customer specifications and revisions shall be distributed by Engineering - one current, permanent copy is to be placed in the Engineering vile.
2.4 A record shall be kept by Engineering of the distribution of customer furnished documents.
In the event of a change, Engineering shall record to whom the revised copies are to be furnished and shall be responsible for determining that the obsolete copy in the file is marked obsolete for use on the order and dispositioned accordingly.
3.0 PPI DRAWINGS 3.1 PPI drawings shall be controlled in accordance with the PPI Quality Assurance Manual.
3.2 Engineering changes in design shall be implemented by revision of the applicable drawing.
o
12/27/78 Rev..
4.0 PROCEDURES / SPECIFICATIONS 4.1 Procedures written for processing special orders, preparation of production documents, control of special processes, plant operating systems or specifications are included in the system.
4.2 The Quality Assurance Manager shall be responsible for approval, maintenance and distribution of procedures / specifications at the Manufacturing facility.
The Chief Engineer shall be respon-sible for the same activities at the service facilities.
5.0 CHANGE CONTROLS 5.1 When a change inquiry is requested, Engineering shall immedi-ately determine the status of the project.
If the change can be made, the Engineering shall have Planning place a Hold notice on the material pending necessary revisions.
If the change cannot be made, the appropriate parties shall be notified of the project status and that the change annot be made.
5.2 Upon receipt of the written change, Engineering (and QA, if applicable) shall review and advise the appropriate parties if the change can or cannot be accomplished.
5.3 Changes initiated internally may be generated by the depart-ment and involve both company and customer approval.
6.0 PROCUREMENT DOCUMENTS 6.1 See NECO 01-104, paragraph 3.0 for control of procurement documents.
7.0 FABRICATION PROCESS SETS 7.1 See NECO 01-105, paragraph 2.0 for Control of Shop orders.
NECO 01-104 12/27/78 Rev.,
PROCUREMENT CONTROL 1.0 PURPOSE To describe the systems,and define responsibilities for approving vendor sources, purchasing materials and services, receiving, material identification, inspection and verification of certified mill test reports and release for shop operations.
2.0 APPROVED VENDORS LIST (AVL)
Radiological Control and Safety shall be responsible for approval, maintenance, and di.stribution of the Approved Vendors List for the service facilities.
The AVL shall indicate those Vendors approved to furnish material or services to special code and customer requirements.
The AVL at the manufacturing facility shall be maintained in accordance with the PPI QA Manual.
3.0 PURCHASING 3.1 PURCHASING REQUISITIONS Purchasing Requisitions for direct materials and services at PPI shall be prepared as described in the PPI QA Manual.
3.2 PURCHASE ORDERS 3.2.1 Purchase Orders at PPI shall be prepared as described in the PPI QA Manual.
3.2.2 Purchase Orders (Exhibit NECO 104-1) shall be prepared by the Purchasing Department.
3.2.2.1 Purchasing shall select sources for materials and services from the AVL or other Vendors who are approved by Radiological Control and Safety subject to a review.
NECO 01-104 12A!7/78 Rev..
3.2.2.2 Prior to issuing to the vendor, all Purchase Orders which contain procedures or design specifications shall be reviewad and initialed by Radiological Control and Safety or the Chief Engineer for order compliance and approval.
3.2.2.2.1 Approved copies of t,e Purchase Order are distributed to appropriate personnel.
3.2.3 Changes to Purchase Orders shall receive the same approval and distribution as the original Purchase Order.
4.0 RECEIVING AND RECEIVING INSPECTION 4.1 Receiving and Receiving Inspection at PPI shall be conducted in accordance with the PPI QA Manual.
4.2 Incoming material shall be checked for damage, quality, and conformance and item identification in accordance with the specific Purchase Order.
4.3 Required test reports and documentation shall be verified as being received and accurate.
4.4 Upon completion of Receiving Inspection, if the applicable part is acceptable, the item is marked " ACCEPTED" with the proper Order number included as necessary.
If not acceptable, the item is marked " HOLD" or " REJECTED" by identification or segregation.
4.5 Upon final disposition, the receiving copy is stamped with the " Material Receival Inspection" stamp.
4.6 Material accepted by Inspection shall be released as appropriate.
NECO 01-104 12/27/78 Rev. *
~
PURCHASE ORDER D U N-S 04143-4573 Nk*
Nuclear E11gilleerillf! C01111N111v.111c.
O P.O. Box 156, S$n Ramon, CA 94583 Executwe Of fice:
O P.O. Box 578. Beatty NV 89003 No. - -12 018 P.O. Box 7246 O
P.O. Box 633. Richland. W A 99352
.... - -... --......... au Louisville, KY 4')207 O
P.O. Box 158. Shef field, IL 61361
'""*J!*.*..*.*l""*,**g'**'"*"*"'
O P.O. Box 146, Morehead. KY 40351 SHIP TO:
TO:
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I GUANT5TV STOCM NO-DE SC RIPTION UNIT PRICE l AMOUNT i
t NUCLEAR ENGINEERING COMPANY, INC.
i FOR RESALc vEs No O
VENDOR'S COPY g_.
LIPPS N ATION AL CORP., NEW ALS ANY. IND, 27733 I
EXHIBIT NECO 104-1 3
-15
~
12/27/78 Rev. -
PROCESS CONTROL 1.0 PURPOSE To describe documents and methods used to implement planning and controls throughout the fabrication and assembly cycle and provide records for final documentation.
2.0 MANUFACTURING DOCUMENTS Fabrication Process Sets shall be prepared and issued by Production using information developed, furnished and approved by the Technical departments.
The orders are identified by a Work Order number applied by Sales to a Project number.
The FPS shall include all relevant basic requirements derived from the order analysis and include drawings, specifications and procedures.
The applicability of the various documents and supplemental instructions are given on the FPS document and reference all inspection, testing and special requirements by procedure numbers or instructions.
2.1 IDENTIFICATION FOR PROCESS CONTROL Material or parts shall be identified throughout assembly by part number, or by assigned item numbers.
To assure trace-l ability, part making is preferred but control by travelers FPS on items being fabricated is also used.
2.2 DISTRIBUTION OF MANUFACTURING DOCUMENTS Fabrication Process Sets (FPS) are distributed by Production that will be produced in the Fabrication Shops.
3.0 PROCESS CONTROL 3.1 The Work Order may travel with the part to each planned operation or a copy be available at the work station.
Upon acceptance of the Product at final inspection and subsequent release, the FPS shall be retained for documentation by QA.
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NECO 01-105 D/27/78 Rev..
2.2 IN-PROCESS INSPECTION 3.2.1 Inspection shall monitor operations and perform product insp~ec-tions and tests in accordance with the sequence of events and document the results on the FPS or on separate reports.
3.2.2 The In-Process Inspector shall inspect completed units of work and review production records for completeness.
3.2.3 In the case of a nonconformance, the Inspector shall apply a Hold tag and prepare and submit a Nonconformance Report to the Quality Assurance Manager to initiate corrective action.
For quality related nonconformances, only the Inspector has the authority to remove the Hold tag and release the item.
4.0 PRODUCT MARKING 4.1 Any special marking shall be applied according to the specified requirements.
4.2 Finished assemblies shall be marked with a nameplate prior to final inspection.
The identification number is applied as part of the final marking and the Project File shall include records of, or be traceable to, any other special marking.
4.3 Final marking may also contain specific serial numbers as speci-fied by customer contracts.
5.0 HANDLING-STORAGE-SHIPMENT 5.1 Finished products shall be protected to avoid damage during subsequent handling.
Special products shall be handled in containers that provide protection during handling and storage.
5.2 Items subject to deterioration shall be stored in enclosed storage areas.
5.3 Special products are cleaned as required h,
..atracts and sub-sequent preservation processes, (paint, etc.) following approved procedures.
o
NECO 01-105 12/27/78 Rev..
5.4 Products are packaged for shipment to meet the standards for Common Carrier Acceptance.
Any special shipping instructions specified in a contract are followed.
Large complex assemblies shall be properly packaged to provide for lifting with cranes or fork trucks when specified by the customer.
6.0
_ CONTROL OF SPECIAL PROCESSES 6.1 Shop operations involving special processes such as hydrostatic tesging, foaming, and other similar processes are performed to PPI 's specifications and procedures.
Conformance to specifi-cations is verified by QA whenever the end result of the process cannot be inspected to determine acceptability.
All processes are performed to comply with applicable ccatract requirements and the PPI QA Manual.
6.2 Subcontractor processes such as welding and Non-Destructive Examination (NDE) are detailed on Purchase Orders to impose required procedure development, approval and use.
Submitted procedures are reviewed and accepted by QA personnel in the same manner as if they were internal documents.
If qualifi-cation of procedures or perconnel is stipulated by the contract, specification or code, these tests are performed and results approved if they comply with the requirements, o
NECO 01-106 12/27/78 Rev.,
INSPECTION AND TEST CONTROL 1.0 PURPOSE To describe the inspection, release for shipment, and test control program used by NECO.
2.0 INSPECTION 2.1 INSPECTION INSTRUCTIONS 2.1.1 Instructions - Inspection shall be performed as prescribed by instructions that provide criteria for acceptance or rej ection.
2.1.2 Drawings - Applicable drawings are provided to each inspection station.
2.1.3 Procedures - Inspection procedures are prepared when re-quired on special products to provide detailed inspection instructions.
2.2 INSPECTION OPERATIONS 2.2.1 Inspection operations at PPI shall be in accordance with the-PPI Quality Assurance Manual.
2.2.2 Receiving Inspection shall be performed as specified in Procurement Control Section NECO 01-104.
2.2.3 In-process inspections may be performed at designated points in assembly process.
Inspection and shop operation steps indicate completion by signoffs and verify conformance to the applicable drawings, procedures and instructions.
I.. spec-tion checks vary from station to station in order to meet the specific needs of each area.
2.2.4 If hold points are specified, work progresses up to the hold point, but not beyond.
Radiological Control & Safety allows the work-to continue after approval is obtained.
If the hold point is waived, Radiological Control & Safety will obtain the necessary confirmation for the job records.
2.2.5 Final i.1pection is performed and signed off by Inspection.
After final inspection, items are released to the ship areas or to hold areas for final review and inspection.
Separate Final Inspection Reports (Exhibit 106-1) and Hydrostatic Test Reports (Exhibit 106-2) are generated by Radiological Control
& Safety if applicable, e
NECO 01-106 12/27/78 Rev..
2.2.6 Acceptance inspection is based on 100% inspection of con-ceptual established critical characteristics.
Should statistical sampling be required or found to be applicable, such -sampling will be conducted in accordance with accepted sampling plans and techniques described in such specifications as MIL-STD 105D.
3.0 TEST CONTROL 3.1 Test Control at PPI shall be governed by the PPI Quality Assurance Manual.
3.2 Pressure retaining items are pressure tested to limits speci-fied by the engineering documentation following established test procedures.
Test requirements are initiated by Engineer-ing, performed by technicians and witnessed by Inspection.
Test results are documented by Operations, accepted by Inspection, with Engineering and Radiological Control & Safety reviewing the test report.
3.3 Mechanical devices may be given a functional test as part of the final inspection procedure.
The device will be checked in either its normal operating mode or in a manner that subjects the items to conditions that are equivalent to or more severe than those encountered in actual service.
3.4 When design proof or qualification testing ic required, it is conducted by outside testing agencies to written procedures.
Written reports are recorded to document the test results and kept on file for customer review.
3.5 Any device or part that fails to perform satisfactorily in the opinion of the QAM or Inspector will be rejected.
4.0 RELEASE FOR SHIPMENT 4.1 Assembled special products or assemblies with requirements for NECO certification and special reporting are placed in the shipping area after final acceptance.
Radiological Control &
Safety reviews the order requirements, special tests, examina-tions, and reports required by the order, prepares certifica-tions and documents as required and releases the Shipper for shipment of the product.
Exhibit 106-1 12/27/78 Rev..
NUCLEAR ENGINEERING COMPANY, INC.
FINAL INSPECTION REPORT DATE:
ITEM:
PER DRAWING:
DEVIATIONS FROM DRAWING:
INSPECTED FOR:
TEST DESCRIPTION:
(Inspector)
R
Exhibit 106-2 12/27/78 Rev. -
g Nuclear EngineerinA Compan,M Inc.
Tw Q 9200 SHELBYVILLE ROAD, SUITE 526 P. O. BOX 7246 LOUISVILLE, KENTUCKY 40207 PVONE f 502) 426-7160 HYT'ROSTATIC/ HALOGEN /FNEUMATIC TEST REPORT DATE:
ITEM SERIAL #
WORKING PRESSURE OF SYSTEM:
HYDROSTATIC TEST PRESSURE:
HYDROSTATIC TEST DURATION:
HYDROSTATIC TEST PROCEDURE:
OR HALOGEN / AIR TEST PROCEDURE:
d REMARKS:
GAUGE NO:
CALIBRATION DUE:
SIGNED:
WITNESS:
APPROVED:
NECO 01-107 12/27/78 Rev..
CALIBRATION OF MEASURING AND TEST EQUIPMENT 1.0 SCOPE This. procedure describes the methods used to assure that tools, gauges, instruments, and other measuring and testing devices are controlled, calibrated and adjusted at specified periods to maintain accuracy within necessary limits.
2.0 IDENTIFICATION Each device or gauge shall be assigned a serial number, labeled and assigned a periodic calibration schedule.
3.0 CALIBRATION 3.1 All calibration of gauges and instruments shall be performed against standards traceable to the National Standards where such standards exist.
3.2 Applicable equipment may include pressure gauges, electronic devices, precision micrometers and calipers.
3.3 Records are kept of the calibration date, due date, tool name and number, calibration frequency, results and calibration certificates.
3.4 A mandatory recall system for devices will be followed.
3.5 An inspection tool checkout and accountability system will prevail and be maintained.
4.0 DISCREPANT EQUIPMENT 4.1 NECO personnel perform simple interim calibration checks such as zero scale and comparison between two similar gauges.
When any device is found to be out of calibration, it shall be recorded on a Nonconformance Report and corrective action is required.
Products previously checked (since the last valid calibration) with defective equipment shall be held until all applicable requirements have been met.
4.2 Equipment that is defective shall be tagged with a " REJECTED" label pending repair, re-calibration or disposal.
o
NECO 01-107 12/27/78 Rev. -
5.0 CONTROL OF SUBCONTRACTOR CALIBRATION Quality Assurance at PPI and Radiological Control &
Safety at NECO shall be responsible for assuring that all vendor sources who perform calibration are capable, and use standards of proper accuracies to accomplish the required calibration.
Certifications shall be furnished for all calibrat~ ion performed by contract sources.
6.0 PERSONALLY OWNED TOOLS All devices used by Quality Control for final acceptance shall be the property of NECO.
Personally owned tools shall not be used for final inspection.
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P
12/27/78 Rev..
NONCONFORMANCE AND CORRECTIVE ACTION 1.0 PURPOSE 1.1 The purpose of this section is to define responsibility for evaluation and disposition of nonconforming items and corrective action.
2.0 DEFINITION 2.1 A nonconformity is a condition in an item that is not accord-ing to requirements of the order or applicable code.
3.0 RESPONSIBILITY 3.1 PPI nonconformance and connection shall be accomplished in accordance with the PPI Quality Assurance Manual.
3.2 It is the responsibility of Operations, Production, Safety and Quality Assurance department personnel to report any nonconforming item.
3.3 When a discrepancy is detected, the Inspector shall a6 ise the workman and Supervisor to stop work on the item.
The Inspector and Supervisor shaJ1 investigate to determine whether the discrepancy is or is not a nonconformance as defined in Paragraph 2.1.
3.4 Nonconforming items arh identified with a "Q.C.
HOLD" tag and segregated.
3.5 If the item can be resolved by rework operations, a revised FPS shall be issued listing the sequence of operations that are to be performed with Inspection as the last operation.
3.6 Nonconformances that can be reworked / repaired to the original specified condition are recorded on Nonconformance Reports (Exhibit 108-1) initiated by the Inspector.
3.7 The NCR reports are for recommendation, resolution, and disposition action development. They are based on code re-quirements, contractual constraints and other pertinent factors.
4.0 ACCEPTANCE AND DISPOSITION OF A NONCONFORMANCE 4.1 The CE shall be responsible for obtaining agreement of rele-vant Operation, Engineering, Sales personnel, and when required, from the customer prior to the approval of the disposition.
The CE shall disapprove any unacceptable proposed disposition.
NECO 01-108 12/27/78 Rev.,
4.2 If the approved disposition is Accepted As Is or Rework, upon completion of the operations and acceptance of the item, the NCR report will be completed per requirements.
4.2.1 After rework or repair operations are carried out by Shop /
Vendor personnel, acceptance inspection is performed, the Hold tag is removed and the item is allowed to continue normal processing.
The Hold tag shall only be removed by Inspection.
5.0 REJECTION OF A NONCONFORMANCE 5.1 When the nonconformance is rejected by NECO, Safety shall mark the item tag Scrap, mutilate items that could be mis-used and send to scrap area.
Acceptable component parts may be removed from an assembly.
6.0 NONCONFORMING PURCHASED MATERIAL (SEE NECO 01-104, PARA. 4.0) 6.1 Items for which correct and complete hardware or software quality requirements are not acceptable shall be detected at Receiving Inspection.
A copy of the Nonconformance Report or suitable inspection report shall be submitted to Purchasing for processing a vendor claim.
7.0 CORRECTIVE ACTION 7.1 As Nonconformance Reports are received and reviewed, Safety shall be responsible for analysis to determine if repetitive errors or major problems should be investigated to prevent recurrence.
7.2 For major problems or repetitive errors, Safety shall initiate a Corrective Action Request (Exhibit 108-2) directed to the Supervisor of the department where the problem occurred.
7.3 The Corrective Action Request shall establish the cause of the error and the action that will be taken to avoid re-petition of the error.
7.4 Corrective Action Requests may also be used to direct Pur-chasing to obtain information as to cause and action that will be taken by Vendor when their performance does not meet NECO requirements.
Exhibit 108-1 12/27/78 Rev. -
NONCONFORMITY MATERIAL DISPOSITION REPORT Fabricating-Shop:
Customer:
NECO P.
O.
No.:
Job hu.:
Contact P.O. No.:
Phone:
ITEM:
Drawing Number (s):
Nonconformance:
Signed:
Date:
(Insp.)
Disposition:
Signed:
Date:
(Engr.)
Date:
Exhibit 108-2 12/27/78 Rev. >
'k'O':
DATE:
FROM:
NUMBER:
SUBJECT:
REQUEST FOR CORRECTIVE ACTION-WE HAVE A PROBLEM!
PLEASE COMPLETE THE BOTTOM HALF OF THIS FORM AND RETURN THE COMPLETED FORM TO QUALITY CONTROL, SPECIFYING CORRECTIVE ACTIONS TAKEN TO PREVENT ggCgggggCg_gF_TgIg_PggpLgM_______________________________________________
CUSTOMER:
PRODUCT /PART NO.
REASON / FILE DISCREPANCY:
1.
PLANNING 2.
ORDER WRITING 3.
DRAWINGS 4.
PROCUREMENT b.
I TI CATION QA ONTROL COMMENTS / RECOMMENDATIONS:
7.
FORMING 8.
FABRICATION 9.
FINISHING
- 10. PROCESS
- 11. OPERATION
- 12. SYSTEM
- 13. PROCEDURE
- 14. METHOD ATTACH g
l SKETCHg OTHERl l
- 15. DESIGN
- 16. GAGING
- 17. DOCUMENT CONTROL l
SIGNED:
QUALITY CONTROL
- 18. PRODUCT CORRECTIVE ACTION TAKEN:
DATE C/A TAKEN:
DATE C/A COMPLETED:
NOT NECESSARY:
AND REASONS WHY NOT:
NOTE: CORRECTIVE ACTION REQUESTS ARE TO BE ANSWERED AND RETURNED TO QUALITY CONTROL ENGINEER WITHIN FIVE (5) WORKING DAYS.
SIGNED:
DATE:
C/A APPROVAL YESj l
NOl l
RCA NUMBER IF NOT APPROVED SEE ATTACHED CC:
ECO 01-109 12/27/78 Rev. -
QUALITY ASSURANCE RECORDS 1.0 SCOPE 1.1 It is the purpose of this section to describe the manner in which final documentation is defined, assembled and retained.
This section provides for the accumulation of complete final documenta' tion, verification of its correctness and establish-ment of retrievability.
2.0 POLICY 2.1 Quality Assurance records shall furnish objective evidence of quality conformance.
All permanent and temporary records are filed in an identifiable order.
As records are completed, they are stored in a suitable environment to protect them from damage and deterioration.
3.0 RESPONSIBILITY 3.1 The Chief Engineer at NECO and the Manager of Quality Assurance of PPI shall be responsible for the accumulation, control and storage of all documentation required by the contract.
4.0 RECORD RETENTION 4.1 Permanent records shall be maintained the life of the equip-ment.
4.2 Temporary records needed to show compliance with this QA Manual are filed in cabinets or separate facilities.
These records are kept until the applicable equipment is in commercial operation for a minimum of five years or as otherwise required after delivery of the item.
After this time, these records may be disposed of by or with concurrence of the Owner.
5.0 FINAL DOCUMENTATION FILE 5.1 The final records to be available and maintained include the following as applicable #.
Permanent Records are identified by an asterisk.
The additional records are non-permanent (temporary).
- l.
Index to Permanent Records file
- 2.
Certified Design Specification when applicable
NECO 01-109 12/27/78 Rev..
- 3.
Stress Report and Stress Calculations
- 4.
Dr; sings (Final as constructed)
- 5..
Data Reports when applicable
- 6.
Copies of all Certified Material Test Reports
- 7.
NDE Records 8.
Quality Control Plan or equivalent 9.
Special Test and Inspection Procedures 10.
Customer order and specification (s) 11.
Work Order
- 12.
Weld Control Records and Weld Repair Results
- 13.
Report of Nonconformance
- 14.
Copy of Welder's and NDE operator's qualifications 15.
Copies of Welding and NDE Procedures and Welding Procedure Qualifications Items 1 through 7 apply for Section III, Division 1, Class 1,
2, CS and MC; Items 2 and 5 apply for Class 3.
6.0 FINAL DOCUMENTATION TO CUSTOMER 6.1 The above documents indicated by an asterisk shall be pro-vided to the customer as applicable.
Items such as Stress Reports, Certified Design Specification and Drawings, may be furnished separate from the documentation package with the product.
NECO'01-110 12/27/78 Rev..
AUDITS 1.0 PURPOSE To define requirements and r'esponsibility for audits to verify compliance with the Quality Assurance Program, this section describes the procedures for internal audits and requirements for Vendor audits.
2.0 INTERNAL AUDIT REQUIREMENTS 2.1 The Quality Assurance System imposes check-points that require records and feedback to evaluate and verify that quality systems, products and manufacturing and inspection operations are satis-factory.
2.2 A system of planned and periodic audits, not to exceed twelve months, shall be performed using written procedures or check-lists by capable personnel not responsible for the areas being audited.
3.0 VENDOR AUDITS 3.1 The QA Manager, the Chief Engineer or designee shall conduct audits of Vendor's capability based on surveys, questionnaires, and performance data.
3.2 Source Inspection may be used on major subcontracts if product complexity is such that quality must be verified at Vendor facility.
i 3.3 An Approved Vendor's list shall be prepared and maintained based upon audits of sourced.
4.0 RESPONSIBILITY FOR AUDITS 4.1 The QA Manager or the Chief Engineer shall initiate Vendor Surveys and Internal Audits.
4.2 The Vice President shall annually initiate audits of the internal Quality Control System to review the status and adequacy of the system.
The audit shall be performed by personnel not in the OA organization.
The Vice President shall designate a person to follow-up that corrective action is taken in areas found to be deficient.
NECO 01-110 12/27/78 Rev.,
.p w
5.0 REPORTS AND CORRECTIVE ACTION 5.1 Detail findings of the audit shall be forwarded to the head of the department audited.
The findings shall include re-sults, recommendations and require an answer describing action taken.
5.2 Summary reports of audits shall be furnished to the Vice President.
5.3 Audit records shall be maintained for follow-up and used to indicate the need for retraining of personnel.
The Quality department shall recommend training requirements, personnel subject to retraining and the department responsible for conducting training sessions.
6.0 TRAINING PROGRAM 6.1 Training programs for personnel performing activities affect-ing quality shall be held periodically.
These sessions shall review program requirements for the area of responsibility of the personnel involved and be directed toward improved under-standing of requirements and assurance of proper implementation of the requirements of this QA Manual.
7.0 ACCESS TO PACILITIES 7.1 The customer and/or his representative shall have practical and reasonable access to NECO facilities for the purpose of evaluation and auditing the Quality Assurance Program and its implementation.
.