ML20041B431
| ML20041B431 | |
| Person / Time | |
|---|---|
| Issue date: | 01/25/1982 |
| From: | Oller R, Potapovs U NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML20041B421 | List: |
| References | |
| REF-QA-99900360 NUDOCS 8202230631 | |
| Download: ML20041B431 (12) | |
Text
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ORGANIZATION:
EXIDE CORPORATION SUMTER, SOUTH CAROLINA REPORT NO.: 99900360/81-01 INSPECTION DATE(S):
12/8-11/81 INSPECTION ON-SITE HOURS: 25 CORRESPONDENCE ADDRESS:
Exide Corporation ATTN: Mr. Charles Reichart Contracts Administrator 101 Gibraltar Road Horsham, PA 19044 ORGANIZATION CONTACT:
Mr. Mark Knechtel, Plant QC Manager TELEPHONE:
(803) 481-8511 PRINCIPAL PRODUCT:
Lead Acid Batteries NUCLEAR INDUSTRY ACTIVITY: The nuclear output of the Exide Corporation including the Sumter, South Carolina plant and the Richmond, Kentucky plant is 2%, based on sales.
Tr. e. Lrm
/-Z.r -82 ASSIGNED INSPECTOR:
R. E. Oller, Components Section (CS)
Date OTHER INSPECTOR (S):
l 6 b% f____
1 -1LP APPROVED BY:
INSPECTION BASES AND SCOPE:
A.
BASES:
10 CFR Part 50, Appendix B; 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 implementation.
DESIGNATED ORIGU'AL Certified By (A.L 7T7hb 8202230631 820129 PDR GA999 EMV*****
99900360 PDR
ORGANIZATJON: EXIDE CORPORATION SUMTER, SOUTH CAROLINA REPORT NO.: 99900360/81-01 INSPECTION RESULTS:
PAGE 2 of 5 i
A.-
VIOLATIONS:
Contrary to paragraph 21.6 of 10 CFR Part 21, Section 206 of the Energy Reorganization Act of 1974, adopted procedures or permissible alternate notice had not been posted in the Sumter, South Carolina plant.
B.
NONCONFORMANCES:
None C.
UNRESOLVED ITEMS:
None D.
STATUS OF PREVIOUS INSPECTION FINDINGS:
1.
(Closed) Deviation A (79-01):
Failure to provide evidence of inspection and acceptability for purchased parts such as separators, spacers, spacer plates and covers, at the E cell assembly line, as required by paragraphs 8.3.2 of the QA Manual, Revision 8, and paragraph 3.7 of procedure QCP-58.0, dated May 19, 1975.
The inspector verified that in accordance with vendor's corrective action response letter, dated August 24, 1979, the principal suppliers of battery parts were advised by letter, dated May 5, 1980, that the products supplied to Exide must show written evidence of final inspection and acceptance.
Observation in the E Line battery assembly area of shipping boxes for spacers, jars and covers received from suppliers, verified that the suppliers are conforming to Exide requirements.
2.
(Closen) Deviation'B.1 (79-01):
Failure to maintain the red lead percentages in four lots of purchased material, within the apparent density range of 20-25 gms/cu.in. as required by paragraph 3.3 of Purchase Requirement No. 2, Section 2, dated September 29, 1977.
The inspector verified that, in accordance with the vendor's corrective action response letter dated August 24, 1979, a review of the problem showed that the test procedure used at the Sumter plant was incorrect.
The Exide material evaluation laboratory at Yardly, Pennsylvania, furnished an approved replacement procedure No. APS-402.
Af ter following this procedure at Sumter, the red lead percentages on purchased materials, were within the required range and no further problems were experienced.
To prevent recurrence of this problem, all nonconforming material analyses are now reported to the Yardly, Pennsylvania Product Engineering Department by use of the Material Review System which provides for a recommended corrective action to be sent to the plant.
.---,.w.
1 ORGANIZATION: EXIDE CORPORATION SUMTER, SOUTH CAROLINA REPORT NO.: 99900360/81-01 INSPECTION RESULTS:
PAGE 3 of 5 3.
(Closed) Deviation B.2 (79-01):
Failure to select completed parts c-twice weekly, inspect them and document this' activity in the Small
~
~
Parts Inspection Record as required by QCP No. 86.1(S), dated December 30, 1977.
The inspector verified that in accordance with the vendor's corrective action response letter dated August 24, 1979, QC personnel were reinstructed and a memorandum was issued by the QC Manager on August 6, 1979, to all QC personnel, to reemphasize the above inspection requirements.
Review of the QC auditor's Small Parts Inspection Records dated June 29, 1979 and November 1981, verified that the twice weekly inspections are being performed.
4.
(Closed) Deviation B.3 (79-01):
Failure to perform the activities of taking daily samples from the E and C casting pots; titrating them, and posting the results on charts at the titration stations as required by QCP No. 86.1.1(S), dated December 30, 1977.
The inspector verified that in accordance with the vendor's corrective action response letter dated August 24, 1979, the previously identified QC Manager's memorandum dated August 6, 1979, to all QC personnel, also reemphasized these procedure requirements.
Review of Calcium Titration Control Charts for the small parts E-Line No. 3 Pot and E Line No. 3A Pot, both for the period of September 28 through November 4, 1981, verified that this activity is being performed in accordance with QC procedure No. 86.1.1(S).
5.
(Closed) Deviatioii B.4 (79-01):
Failure to monitor the assembly lines on a daily basis and record the inspection results on the Stationary Inspection and Process Verification Records for Lines C and E, as required by QCP No. 102.3(S), dated February 13, 1978.
The inspector verified that, in accordance with the vendor's corrective action response letter dated August 24, 1979, procedure QCP No.
102.3(S) was revised on April 9, 1979, which changed the daily inspection and recording requirement for the C and E assembly lines to a frequency of two times a week.
Review of the current Stationary Inspection and Process Verification Records dated November 27, 1981 and December 4, 1981, for the C and E lines, verified that the QC monitoring is being performed as required by the revised procedure.
6.
(Closed) Deviation C (79-01):
Failure to bring discrepancies found during Quality Control review of four purchase orders, to the attention of the Purchasing Department so corrective action could be taken, as required by QCP No. 30.7, dated November 1, 1978.
ORGANIZATION: EXIDE CORPORATION SUMTER, SOUTH CAROLINA REPORT NO.: 99900360/81-01 INSPECTION RESULTS:
PAGE 4 of 5 The inspector verified that, in accordance with the vendor's corrective 2 --
action response letter dated August 24, 1979, the practice of directing purchase orders containing discrepancies back to the originator in Production Planning has been discontinued.
The discrepant purchase orders are now sent to the Purchasing Department for correction and issue of a revised P.O.
Review of six P.O.s dated i
November 2, 1981, verified that they were reviewed by QC.
Two of the P.Os were found to contain discrepancies and were returned to purchasing where correct revised P.O.s were issued.
E.
OTHER FINDINGS OR COMMENTS:
1.
Manufacturing Process Control - The inspector reviewed seven sections of the Exide QA Manual which were applicable to the C and E lines stationary batteries parts manufacture, assembly, testing, inspecting, and monitoring.
Observations were made of battery grid and small parts casting, grid pasting and finishing, QC chemical sampling, testing and monitoring, battery assembly, and final inspection.
Review also included:
a customer purchase specification; four Sumter plant QC procedures; three calcium titration control chart records for grid casting pots; a record of the daily report of paste mixing; three QC records of the pasting and finishing process checklists, and two records of QC department stationary product inspection reports.
Within this area,'no nonconformances to NRC or QA program requirements were identified and no unresolved items were identified.
2.
Change Control - The inspector reviewed the QA Manual Section 3 " Design Documentation and' Change Control" which was appliable to changes in engineering generated manufacturing documents, QC and QA documents.
i A review was also made of:
an administrative procedure QAP-55.0 covering document control; two records of Quality Control Notices dealing with changes to QC procedures; two records of Engineering Change Requests covering requests for changes in two Manufacturing Requirements Sheets.
Within this area, no nonconformances to NRC or QA program requirements l
were identified, and no unresolved items were identified.
Review and discussions also established that only the Quality Control Procedures were totally generated, approved, and revised at the Sumter plant level.
While changes to engineering, manufacturing, and QA documents could be requested at plant level, the final approval and changes were controlled at the Yardly and Horsham, Pennsylvania engineering, quality assurance, and corporate levels.
l l
ORGANIZATION: EXIDE CORPORATION SUMTER, SOUTH CAROLINA REPORT NO.: 99900360/81-01 INSPECTION RESULTS:
PAGE 5 of 5
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3.
Nonconformances and Corrective Action - The inspector ~ reviewed two sections of the Exide QA Manual wuich were applicable to control and disposition of deficiencies found in materials at receiving inspection, parts during manufacture and assembly, and final inspection of the batteries prior to shipment.
To verify that nonconforming 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 administrative QA procedures; a Material Review Board Log; ten Material Review Reports; a Corrective Action Request Log; four Corrective Action Requests; a QC Red Tag Log; two completed Red Tags; and a QC Area Controller's list of outstanding Red Tags for November 1981.
Observations were made of a hold area for items held for Material Review Board Action, and a red tagged battery hold area.
Within this area, no nonconformances to NRC and QA program requirements were identified, and no unresolved items were identified.
4.
10 CFR Part 21 - The inspector reviewed the administrative procedure QAP-62.0 which provided instructions for the plant QC Manager's completion of a Material Review Report for nonconformances to the corporate Quality Assurance, and of the QA Manual paragraph 15.12 which provided a procedure for QA to evaluate and report nonconformances in accordance with 10 CFR Part 21.
Observations established that existing posting was in violation of paragraph 21.6 of 10 CFR Part 21, in that only a copy of the regulations was posted.
Section 206 of the Energy Reorganization Act of 1974 and adopted procedures (or permissible alternate notice) were observed to be not posted.
Prior to the end of the inspection the posting requirements of 10 CFR Part 21 were met and no written response to this violation has been requested.
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