ML20040B566
| ML20040B566 | |
| Person / Time | |
|---|---|
| Issue date: | 12/31/1981 |
| From: | Oller R, Potapovs U NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML20040B555 | List: |
| References | |
| REF-QA-99900384 NUDOCS 8201260197 | |
| Download: ML20040B566 (15) | |
Text
1 dRGANIZATION:
G&W EAGLE SIG?iAL INDUSTRIAL CONTROLS DAVEt4 PORT, IOWA REPORT NO.: 99900384/81-01 INSPECTION DATE(S): g/28 10/2/81 INSPECTION ON-SITE HOURS.: 28 CORRESPONDENCE ADDRESS:
G&W Eagle signal Industrial Controls ATTft: Mr. W. W. Huppert President 736 Federal St.
Davenport, Iowa 52803 ORGANIZATION CONTACT:
Mr. J. M. Hawkinson, Supervisor, QA TELEPHONE:
(319) 326-8111 PRINCIPAL PRODUCT:
Industrial Timers and Counters NUCLEAR INDUSTRY ACTIVITY:
This plant processes both nuclear and nonnuclear orders under the ame QA program. The final shipment of the last nuclear order was in July 1981.
Currently, there are no nuclear orders in process.
ASSIGNED INSPECTOR:
/
A
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R. E. Oller, Comporents Section (CS)
Date OTHER INSPECTOR (S):
I APPROVED BY:
f/
h'b/-h }
[ PoQpk;/s, ActiWg/ Chief, CS Date INSPECTION BASES AND SCOPE:
A.
BASES:
10 CFR Part 50 and 10 CFR Part 21.
B.
SCOPE:
Status of previous inspection findings; manufacturing process control; change control; nonconformances and corrective action; and 10 CFR Part 21.
U Certifi:d Dy 8201260197 820106 PDR GA999 ENVGULW 99900384 PDR
ORGANIZATION:
G&W EAGLE SlGFDL ZNDUSTRZAL CONTROLS DAVENPORT, IOWA REPORT NO.: 99900384/81-01 INSPECTION RESULTS:
PAGE 7 gf 7 A.
VIOLATIONS None B.
NONCONFORMANCES:
1.
Contrary to the corrective action commitment in Eagle Signal's response letter dated April 22, 1980, Section 9.3.6.5 " Sampling Plan" of the Quality System Manual (QSM) had not been written (See paragraph D.2.).
2.
Contrary to the corrective action commitment in Eagle. Signal's response letters dated April 22 and May 15, 1980, Section 9.3.1.5 " Quality Auditing" of the QSM, had not been revised to include all of the elements of a system audit program (See paragraph D.10.).
3.
Contrary to the corrective action commitment in Eagle Signal's response letter dated May 15, 1980, a new section of the QSM to provide an overall product test control program, had not been written (See paragraph D.10).
C.
UNRESOLVED ITEMS:
None D.
STATUS OF PREVIOUS INSPECTION FINDINGS:
1.
(Closed) Violation (80-01):
Contrary to paragraph 21.21 of 10 CFR Part 21 and customer purchase order No. 282-TG108, Revision 00, the Eagle Signal Division had not adopted apprcpriate procedures to provide for evaluating deviations or informing the licensee or purchaser of such deviations.
The inspector verified that in acco-dance with the vendor's response letter dated April 22, 1980, a formal procedure, " Product Safety Review Board" was written, approved on July 28, 1980 and added to the Quality Systems Manual as Section 9.3.9.2.
Review of this procedure verified that it provided adequate measures for evaluating and reporting of 10 CFR Part 21 conditions.
2.
(0 pen) Deviation A.1 (80-01):
Failure to use sample tables from an Inspection Manual 5pecification approved by the QA engineer, while per-forming receivir.g inspection, in accordance with paragraph 1.d of Section 9.3.4.1 of the Quality Systems Manual.
The inspector verified that in accordance with the vendor's response letter dated April 22, 1980, the sampling plan currently in use is based on Mil-Std-105D.
Sampling tables have been developed and are being implemented, and are contained in the QA Engineer approved Inspection Manual Procedure 9.2.0.4.
However, contrary to the vendor's commitment, the Quality Systems Manual Section 9.3.6.5 which would
ORGANIZATION: G&B EAGLE SIGNAL INDUSTRfAL CONTROLS DAVENPORT. IOWA REPORT NO.: anonnqq3 f 93_n3 INSPEC ION RESULTS:
PAGE 3 of 7 contain the sampling plan, has not been written (see B.1 above).
3.
(Closed) Deviation A.2 (80-01):
Pailure to date, initial and stamp five packing tickets after completion of receiving inspection for materials, in accordance with paragraph 1.e. of Section 9.3.4.1 of the Quality Systems Manual (QSM).
The inspector verified that in accordance with the vendor's response letter dated April 22, 1980, Section 9.3.4.1 of the QSM was revised on July 18, 1980, to change the marking requirement from dating, initial-ing and stamping of each item line on the packing ticket, to stamping and dating only once on each packing ticket, after acceptance of part or all of the material.
Observations verified this practice was being implemented.
4.
(Closed) Deviation B.1 (80-01):
Failure to apply a label to the Digital Multimeter S.N. GT-1007, to indicate the date of last calibration, by whom it was calibrated and when the next calibration was due, in accordance with Item 6 of Section 9.3.7.3 of the Quality Systems Manual.
The inspector verified that in accordance with the vendor's response letter dated April 22, 1980, the subject device was properly labeled prior to the end of the previous inspection.
Records show that it was currently calibrated on September 21, 1981, on a three month fre-quency.
5.
(Closed) Deviation B.2 (80-01):
Failure to enter on record cards each calibration result as it was accomplished for DC Ammeter S.N. T-1001 and DC Voltmeter S.N. T-3001 in accordance with Item 9 of Section 9.3.7.1 of the Quality Systems Manual.
The inspector verified that in accordance with the vendor's response letter dated April 22, 1980, the two above devices are being calibrated and the results are being properly recorded.
The devices were currently calibrated on September 24, 1981, and September 29, 1981, respectively.
6.
(Closed) Deviation B.3 (80-01):
Failure to identify the procedure governing the service and calibration, on the Instrument Identification Record Card of DC Ammeter S.N. T-1001, DC Voltmeter 5.N. T-3001 and the AC Variac S.N. T-2015, in accordance with Annex III to Section 9.3.7.3 of the Quality Systems Manual.
The inspector verified that in accordance with the vendor's response letter dated April 22, 1989. the applicable EWB-804 calibration nroce-dure identification was entered on the Instrument Identification Record Cards for the above instruments. The balance of record cards are in the process of being updated.
l ORGANIZATION: G&W EAGLE SIGNAL INDUSTRIAL CONTROLS DAVENPORT, IOWA REPORT NO.:99900384/81-01 INSPECTION RESULTS:
PAGE 4 of 7 7.
(Closed) Deviation B.4 (80-01):
Failure to write in the " Instrument Indication Block" on the record card the measurement observed on the inspected instrument during testing at the standard calibration point for DC Ammeter S.N. T-1001.
The inspector verified that in accordance with the vendor's response letter dated April 22, 1980, the actual test values are now being recorded for the above type instrument during testing at the calibration point.
8.
(Closed) Deviation E.1 (80-01):
Failure by the OA Engineer to provide an Inspection Checklist to the Inspection Department for the Contact Stack, Part No. HP-50-117, at the time of engineering release, in accordance with Section 9.3.6.1 of the Quality Systems Manual.
The inspector verified that in accordance with the vendor's response letter dated April 22, 1980, the Inspection Check List for the HP-5 Cycle-Flex Unit, which includes the HP-50-117 subassembly, was upgraded on May 5,1980 and approved for use on April 14, 1981.
Review of current check list records verified that the upgraded checklist was provided to the Inspection Department and that it is being implemented.
9.
(Closed) Deviation E.2 (80-01):
Failure to include in the HP-5 Inspection Checklist for Timer, Part No. HP-57A6 the required electrical tests and a description of the procedure and setup of the test equipment, in accordance with paragraph d. of Section 9.3.6.1 of the Quality Systems Manual.
(
The inspector verified that in cocordance with the vendor's response letter dated April 22, 1980, the functional electrical test proceaures, which include the procedure and setup for the five HP-5 Cycl-Flex-Timer test racks, have been consolidated into one book, and each inspector has a copy of the book.
10.
(0 pen) Deviation D (80-01):
Failure to include in the QA Program the areas of Test Control, Corrective Action, QA Records and Audits, in accordance with Criterion II cf Appendix B to 10 CFR Part 50, and a customer's purchase order.
The inspector verified that in accordance with the vendor's response letters dated April 22, 1980, and May 15, 1980, the following actions have occurred:
D.1. The Quality Systems Manual (QSM) new Section 9.3.2.1, " Corrective Action Internal" was prepared and approved for use on February 13, 1981.
This item is closed.
\\
J ORGANIZATION: G&W EAGLE SIGNAL INDUSTRIAL CONTROLS DAVENPORT, IOWA REPORT NO.:9990038481-01 INSPECTION RESULTS:
PAGE gg7 0.2.
The QSM new Section 9.3.9.3, " Document Retention Program" was prepared and approved for use on February 19, 1980.
This item is closed.
D.3.
The QSM Section 9.3.1.5, " Quality Auditing" which covers product audits, has not been revised to include all elements of a system audit as committed to in the vendor's letter dated May 15, 1980.
This item remains open.
See B.2 above.
D.4.
A new QSM Section No. 9.3.0.3 or 9.3.9.2 to provide an overall product test control program has not been written as committed to in the vendor's letter dated May 15, 1980.
This item remains open.
See B.3 above.
11.
(Closed) Deviation E (80-01):
Failure to establish measures to assure that devices such as gram gauges, feeler gauges, torque wrenches and torque screw drivers, used in activities affecting quality, are con-trolled and calibrated, in accordance with Criterion XII of Appendix B to 10 CFR Part 50.
The inspector verified that in accordance with the vendor's response letters dated April 22, 1980 and May 15, 1980, a new QSM Section 9.3.7.1, " Mechanical Measuring Equipment," was written and approved on May 20, 1981, to provide measures to control, calibrate and document all mechanical gages.
12.
(Closed) Unresolved Item D.3.b (80-01):
It appeared that two similar forms No. EWB-270 " Material Inspected Record" and No. EAG-270
" Historical Record" were used by Receiving Inspection for the same purpose without specific reasons for using the two forms.
Also both of these forms provided for inspection dispostion of each line item, however, the current practice is to use only one inspection stamp dispestion per page instead of by line item.
The inspector determined that the title and number of one form was changed to " Historical Daily Part Inspection Record" No. EAG-270A to provide a permanent part identity re:ord while the other form was changed to " Daily Material Inspection Record" No. EAG-2290 to provide for a daily inspector activity record.
Observation verified that both of these forms were in use.
13.
(Closed) Unresolved Item E.3.b (80-01):
Although Section 9.3.1.5 of the Quality Systems Manual indicates that product audit characteristics refer to standards provided in the Inspection Manual No. 9.2.0.0., it was determined that the Inspection Manual had not been written.
The inspector determined that the Inspection Manual No. 9.2.0.0. has been complied and is in a review and revision status.
Completion is expected within a few months.
I l
ORGANIZATION: GAW EAGLE SIGNAi. INDUSTRIAL CONTROLS DAVENPORT, IOWA REPORT NO.: 99900384/81-01 INSPECTION PdSULTS:
PAGE 5 of 7 E.
OTHER FINDINGS OR COMMENTS:
1.
Manufacturing Process Control The inspector reviewed four sections of the Eagle Signal Quality System Manual which were applicable to material receiving, manufacturing, patrol and final inspection, and final electrical tests for timers and counters.
The same QA program covers items manufactured for both nuclear and non-nuclear service.
Observations were made on in-process assembly, inspection and electrical tests of both electro-mechanical timers and printed circuit boards for solid state products, using manufacturing route sheets for control of both subassemblies and component assemblies.
Review also included: a soldering standard; manufacturing route sheets for control of subassemblies and component assemblies; seven daily inspection reports of audit; patrol inspection check lists; a weekly summary record of inspections for electro-mechanical components; a book of technical methods; and a book of electrical inspection test proce-dures.
Within this area, no nonconformances to NRC a-d quality program require-ments were identified, and no unresolved items were identified.
2.
Change Control r
The inspector reviewed three sections of the Quality System Manual which were applicable to changes in new designs, existing models and drawings.
A review was also made of an engineering specification change procedure and the related records consisting of 12 engineering change orders, and a product model upgrading record log book, to verify that changes in engineering, production, inspection and test activities were docu-mented, reviewed and approved as required by Quality System Program.
Within this area, no nonconformances to NRC and the quality program requirements were identified and no unresolved items were identified.
3.
Nonconformances and Corrective Action The inspector reviewed four sections of the Quality System Manual which were applicable to the control and disposition of deficiencies in in-process subassemblies and component assemblies for timers and counters and also for those units in inventory which require upgrading.
ORGANIZATION:
G8W EAGLE SIGNAL INDUSTRTAL C0t4TROLS DAVENPORT, IOWA REPORT NO.: 99900384/81-01 INSPECTION RESULTS:
PAGE 7 of 7 To verify that nonconfoming items were reviewed and accepted, rejected, repaired or reworked, and that conditions adverse to quality, including the cause, are promptly identified and corrected, a review was made of:
two material deviation reports; a record of hold tag and non-conformance; six corrective action requests, and four nonconformance review reports. Observations were made of segregated hold areas, and the nonconforming items therein, in the receiving inspection area, I
fabrication department and the electro-mechanical inspection area.
Within this area, no nonconformances to flRC or quality program require-ments were identified, and no unresolved items were identified.
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