ML20054G514
| ML20054G514 | |
| Person / Time | |
|---|---|
| Issue date: | 05/27/1982 |
| From: | Barnes I, Oller R NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML20054G501 | List: |
| References | |
| REF-QA-99900225 NUDOCS 8206210628 | |
| Download: ML20054G514 (12) | |
Text
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ORGANIZATION:
THE FOXBORO COMPANY HIGHLAND PLANT EAST BRIDGEWATER, MASSACHUSETTS j
REPORi INSPECTION INSPECTION NO..
99900225/82-01 DATE(S) 4/6-8/82 ON-SITE HOURS: 24 CORRESPONDENCE ADDRESS:
The Foxboro Company ATTN:
Mr. C. A. McKay, Executive Vice President Technology Division 38 Neponset Ave.
Foxboro, MA 02035 ORGANIZATIONAL CONTACT:
Mr. F. Leathers, Corporate QA Manager, Field Operations
)
TELEPHONE NUMBER:
(617) 543-8750 PRINCIPAL PRODUCT: Electronic Process Control Instrumentation and Allied Equipment.
NUCLEAR INDUSTRY ACTIVITY: The Highland Plant Nuclear production output is 2.5% based on sales.
ASSIGNED INSPECTOR: I 5-2 7-f2.
4 R. E. Oller, Reactive & Component Program Section Date (R& CPS)
OTHER INSPECTOR (S):
APPROVED BY:
,-hl' fM#
C P4' I. Bardes, Chief, R& CPS Date' INSPECTION BASES AND SCOPE:
A.
BASES:
B.
SCOPE:
Status of previous inspection findings; manufacturing process control, and nonconformances and corrective action.
l PLANT SITE APPLICABILITY:
Not identified.
DESIGNATED ORIGINAL n., lr I ['[l ll l0 Y -
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8206210628 820603 PDR GA999 ENVFOXB 99900225 PDR
ORGANIZATION:
THE FOXBORO COMPANY HIGHLAND PLANT EAST BRIDGEWATER, MASSACHUSETTS REPORT INSPECiiON NO.:
99900225/82-01 RESULTS:
PAGE 2 of 6 A.
VIOLATIONS:
None B.
NONCONFORMANCES:
None C.
UNRESOLVED ITEMS:
None D.
STATUS OF PREVIOUS INSPECTION FINDINGS:
1.
(Closed) Deviation A (80-01):
Failure to revise the workmanship standard by January 1, 1978, to require a minimum of one and one-half thread protrusions for all nuts and bolts regardless of use or configu-ration.
Also, failure to perform a minimum of four audits in 1978 for Department No. 704, to ensure that inspectors were doing a proper inspection job.
Both of these actions were committed to in the Foxboro Company corrective action response letter dated October 14, 1977.
The NRC inspector verified that in accordance with Foxboro's response letter dated May 9, 1980, Standard No. 14200A, Section 5.2, was revised, effective December 13, 1977, by the addition of the statement, " Screw extends past nut or retainer a minimum of 1 threads, except when such projections interferes with the design function." Also, the Highland Plant procedure No. 54.72 "Nonconformance Reporting for Documentation Conflicts," was initiated on March 17, 1978 to provide preventive action.
The NRC inspector also verified that Procedure No. 54.48, " Highland Mini-Audit Procedure," was revised on August 30, 1978, to change the audit frequency for all areas to twice annually.
Review of current records of audit verified that Department 704,
" Inspection," was audited during three quarters of 1981 to meet the revised procedure requirements.
ORGANIZATION:
THE FOXBORO COMPANY HIGHLAND PLANT EAST BRIDGEWATER, MASSACHUSETTS REPORT INSPECTION NO.-
99900225/82-01 RESULTS:
PAGE 3 of 6 2.
(Closed) Deviation B (80-01):
Failure to log all of the monthly preventive maintenance in the PMC schedule attached to the folder on the automatic sequencer machine, as required by Section 0, paragraph II of the Operation and Maintenance Procedure No. 14100F dated March 1976.
The NRC inspector verified that in accordance with Foxboro's response letter dated May 9, 1980, the log and the procedure are now under the computerized preventive maintenance operations control and are maintained in the PM0 office.
The sequencer machine now has a PM0 "due date sticker" attached to it.
The former Procedure No. 14100YF has been superseded by Plant Procedure No. 56.01, " Test Equipment Control, Calibration and Maintenance Department," effective February 23, 1982.
This procedure provides department policy.
The actual PM0 for the sequencer machine is provided in Procedure " Tool No. 206079," which provides for PM0 on a weekly basis.
Review of audit records verified that the Sequencer Department was audited on October 2, 1981.
Observations verified that a current weekly PM0 sticker was attached to the sequencer.
3.
(Closed) Deviation C (80-01):
Failure to attach a maintenance checklist identifying the preventive maintenance, personnel performing it, and date of accomplishment, to the tool folder, for the automatic inserter machine as required by Section E, paragraph 2, of the Operations and Maintenance Procedure No.
14101BK, dated June 21, July 29, and 30, and August 2, 1976.
The NRC inspector verified that in accordance with Foxboro's response letter dated May 9, 1980, this condition for the inserter machine was similar to that for the sequencer and the corrective and preventive actions were the same.
The weekly PM0 log and Procedure
" Tool No. 206075" are maintained in the PM0 office.
The inserter has a currently weekly PM0 sticker attached to it, and this department was also audited.
4.
(Closed) Deviation D (80-01):
Failure to place the " circle" inspection stamp at the applicable operation on four Production Routing Cards for items identified as "0kay for Stock," as required by Foxboro Procedure No. 52.2L, dated January 31, 1980, and QC Inspection Instruction No. 24100LQ, Revision B.
ORGANIZATION:
THE FOXBORO COMPANY HIGHLANDS PLANT EAST BRIDGEWATER, MASSACHUSETTS REPORT INSPEGl10N NO.
99900225/82-01 RESULTS:
PAGE 4 of 6 The inspector verified that in accordance with Foxboro's response letter, dated May 9, 1980, QCII No. 24100LQ was revised on March 25, 1980, to clarify it and correlate it with procedure No. 52.2L by adding "It is not necessary to ' circle' stamp a final inspection operation if the '0K for Stock' stamp is to be used." Review of records verified that four quarterly audits of this Department, No. 782, were performed during 1981 and 1982 to provide preventive action.
5.
(Closed) Deviation E (80-01):
Failure to adhere to the require-ments of the QC&M Procedure No. 14100YB, Revision B, regarding the wave solder machine speed, calibration, nozzle pressure and tempera-ture, and wave solder cleanliness sample boards had not been tested weekly.
The inspector verified that in accordance with Foxboro's response letter dated May 9, 1980, a review by Foxboro determined that the wave solder machine settings were correct, as found, but the procedure had not been updated to reflect the new parameters.
To correct this condi-tion, Procedure No. 14100YB was revised, effective April 2, 1980, to provide the correct ranges of the parameters.
The wave solder cleanliness sampling board tests were reinstated, and are being performed, as verified by weekly test records maintained in the chemical laboratory.
Preventive action was provifed by performing four audits of the chemical laboratory during 1981.
6.
(Closed) Unresolved Item D.3.b (80-01):
The available records in manufacturing process control did not indicate that Quality Control had monitored and reviewed all process tools and equipment used in manufacturing.
The inspector determined that this audit activity is controlled by Procedure No. 54.44 " Manufacturing Process Monitor"; the QCII form No. 24000A which delineates QC monitoring activities with regard to process tools and equipment, and the mini-audit record form.
Review of audit record forms for the PM Department shows that Item 2 " Tools Calibration / Numbered / Maintained" was checked as acceptable.
These records show the PM0 Department No. 752 was audited twice a year on a quarterly basis.
ORGANIZATION:
THE FOXBORO COMPANY HIGHLAND PLANT EAST BRIDGEWATER, MASSACHUSETTS REPORT INSPECTION NO.-
99900225/82-01 RESULTS:
PAGE 5 of 6 7.
(Closed) Followup Item 0.4 (80-01):
The manufacturing process control drawings in use in the cable area were not consistent in specifying overall cable lengths.
Review of this matter during this inspection verified that the drawing in question, No. B0136EC, Revision B, contained directions for determining the overall cable length and the specific length did not need to be put on this drawing.
Other drawings could have the specific lengths of cable identified on them depending on the application, or if specified by the " Highland Manufacturing Service Group," which makes up drawings used for custom requirements.
This variation in identifying overall cable length, does not appear to constitute a problem.
E.
OTHER FINDINGS OR COMMENTS:
I 1.
Manufacturing Process Control:
The inspector reviewed nine sections of the Highland Plant Quality Program Manual, Issue No. 8, which were applicable to parts manufacture, assembly and inspection of electronic process control instrumentation.
Observations were made of the burn-in and inspection of integrated circuits, manufacture and inspection of printed circuit boards; automatic and manual insertion of components in the PCB's; first piece inspection; assembly and final inspection of instruments and power supply units, and the calibration and preventive maintenance status of manufacturing machines and process and inspection tools.
To verify that parts, subassemblies and assembled instruments were controlled, assembled, inspected, tested and documented in accordance with the Quality Program, a review was made of:
nine plant procedures; Shop Travel Cards (travelers) and/or Factory Operations (Long Form) sheets accompanying the processing of integrated circuits; insertion of components in PCB's, assembly of power supply units, first piece inspection of PCB's, and final inspection of completed instruments.
Within this area, no nonconformances or unresolved items with respect to NRC and the Quality Program requirements were identified.
2.
Nonconformances and Corrective Action:
The inspector reviewed two sections of the Highland Plant Quality Program Manual which were applicable to the control and disposition of nonconformances found by inspections and tests in procured material and items, in process parts, and final assembled instruments.
ORGANIZATION:
THE FOXBOR0 COMPANY HIGHLAND PLANT EAST BRIDGEWATER, MASSACHUSETTS
~
REPORT INSPECTION NO.:
99900225/82-01 RESULTS:
PAGE 6 of 6 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:
three plant procedures; records of eight MRB completed Nonconformance Action Requests common to procured items, and records of 10 MRB completed Nonconformance Reports common to deficiencies found in items in process.
Observations were made of the area used for segregating non-conforming items pendirig MRB disposition, and the identification of the items by red tags.
Within this area, no nonconformances or unresolved items with respect to NRC and the Quality Program requirements were identified.
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