ML20117F218
| ML20117F218 | |
| Person / Time | |
|---|---|
| Site: | Waterford  |
| Issue date: | 05/20/1977 |
| From: | Boswell C WALDINGER CORP. |
| To: | |
| Shared Package | |
| ML20117F125 | List: |
| References | |
| FOIA-84-205 SQCP-15.1-2, NUDOCS 8505130171 | |
| Download: ML20117F218 (15) | |
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'*' I THE WA1.DiNGER CORPORATION
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-- j Date 05/20/77 Approved By:
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TITLE PAGE D/
EEASCO SERVICES INCORPO R ATED QUALITY ASSURANCE ENGINEERING Manual No:
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[ TTTLE _NOtiCONFORMAliCE COTTTROL -
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g SHOP QUALITY CONTROL MANUAL Procedure SCCP 15.1-2 L
WATERFORD III 1.0 Purnose 1.1 To provide the measures to identify, review, control and disposition materials, itens, systems and processes that do not conform to the drawings, specifications or codes such that their use or 1.nstallation is prevented.
2.0 scope 2.1 This procedure applies to nonconformances discovered during the receiving, storage and fabrication of HVAC duct, material and structural support hangers fabrication shop.
at the 3.0 References 3.1 The Waldinger Corporation Quality Assurance Manual 3.2 Field Quality Control Manual 3.3 Pield Work Procedures Manual 3.4 shop Quality Control Manual 3.5 Shop Work Procedures Manual 4.0 Definitions 4.1 Nanconformance Report = dOCuenants a deficiency in characteristic, documentation, or procedure which renders the quality of an item unacceptable or indotorminate (hereaf ter referred to as an NCR).
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Procedure SCCP 15.1-2 THE WALDINGER CORPORATION 05/20/77, Rev. O Page 2 of 8 4.2 Deficiency Re;crt - d:::mants c:nditiens which are not :ounc := ce a::eptable (hereaf ter referred to as a DR).
A DR en c cvaluated by the Quality Assurance Mant;c: :: hi: f::ignas m:y be pr: cessed as a n nconf :=nne..eps :.
4.3 Ncncenformance - A cefi: ency in casracteristic,
- cumenta::en, :: ::::edure hl=h rendars the quality cf aa
" accepta:1e c: Indeterminate.
Exa=ples cf nenc:nic:msnce includa:
physical defects, test failures, incorrect or inadequate documentation, and deviations from prescribed 3
processing, inspecti:n c test procedures.
6 4.4 Inspection - A phase of quality control which by means of examinatien, cbservation or measurement, determines the cenicrmance of materials, supplies, components, parts, appurtenances, systems, processes or structures to centract quality requirements.
4.5 Rework - The process by which a nonconforming item is made to confor= to a prior specified requirement by completion, remaking, reassembling or other corrective means.
g 4.6 Repair - The p cess of restering a ncnconforming J
characteristic te a conditien such that the capability of an item to functicn reliably and safely is unimpaired, even though that item still may not conform to the original requirement.
4.7 Use-as-is - A disposition which may be imposed for a nonconformance when it can be established that the discrepancy will result in no adverse conditions and that the item under consideration will continue to meet engineering functional requirements including performance, maintainability, fit, and safety.
i 4.8 Reject - The action taken to eliminate a nonconforming item from its specified use.
4.9 Item - Any level of unit assembly, including structure, system, subsystam, subassembly, component, part, or material.
4.10 Material Review Board - Composed of the Project Manager, the Quality Control Supervisor, who is designated as Chairman, and the client, or their representatives, for dispositioning use-as-is and repair disposition.
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I'tocedutu WJP i';. 2 1 TME WALD4NGER CORPORA 1MN 05/;0/77, Rev. 0 Page 2 of 8 5.0 Responsibilities 5.1 The quality control inspector is responsible for identifying, docu:v2= ting, and distrlhuting daf::Lency reports, and nonconformance reports, and assuring that segregation of nonecnfor=.tng 1 cms is. ace:mplasr.ed.
5.2 The Quality Centrol Sucervisor is responsi.bie f 0:
identifyang and processing n:nconfor:uince reports and approving Mauria.L P.eview Eonrd dispos: u cnr..
5.3 Asst. Vice Prasident - Nunager/Faarication is responsable for providing Material Review Scard dispositions for nonconforming items, and assuring that t.he required corrective action La accomplishad.
5.4 The Manager of rabrication and Delivory is responsible for identifying nonconformances during receiving, i
storage and f abrication processes and informs the Qualit.y Control Supervisor of the nonconformAng 1
conditions.
6,0 prc:adure 6.1 An NCR is generated by the quality control inspector or Qualley Control Supervisor in accordance with Appendi:: "A" and as determined by a review of the deficiency report (CR) as described by Reference 4
2.4, Shop Quality Control Manual, Procedure UCC?
15.1-1.
An NCR may be generated by the Quality control supervisor without the use of a DR dependL=g upon the nature or criticality of the nonconformance.
6.1.1 At such time that a nonconforming condition exists, the Quality control Super' visor has t:he authority to stop the fabrication or installation, activities, as necessary.
The work stoppage is innsediately Esported to the Amst. Vice President - Manager /rabrication and the
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Quality Assurance maJar.
6.1. 2 '
The quality control inspactor places a hold tag on the nonconforming item as described in tha referenced QualLty Assurance Manual, Procedure QAP 15.0.
Smaller itama may be collected in a container and a hold tag placud on the container.
The nonconforming items i
are transferred to a holding area or segregated.from acceptable items.
Barriers may be utill:ed to segregate the nonconforming material.
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THE WALDINGER CORPORATION Procedure SQCP 15.1-2 05/20/77, Rev. O Page 4 of 8 6.2 When the NCR is generated by the Quality Control Inspector, the Quality Centrol Supervisor reviews the NCR for complacaness and correctness, and assures that the noncenferming items have been l
described in accordance with the following requirementst i
6.2.1 an accurate description of the characteristics which make the item nonconforming,.(sema of these characteristics are incorrect material, dimensions, appearance, processes, drawing deviations, or unknown conditions);
i 6.2.2 includes information contributing to the conditions which caused the nonconformance; 6.2.3 includes details or sketches of the exact location in the f abricated assembly or and product; l
6.2.4 identifies physical location (s) of the nonconferning i' tam that may help to locate the item in addition to the information included in block 5 of the NCR form, (i.e., welding area, forming
! sJ area, packaging area, etc.) and pro-l cessing phase, (i.e., Receiving, Storage, Fabrication, etc.);
6.3 once signed in block 9 of the NCR form, the NCR shall be assigned an identifying number and logged by the Quality Control Supervisor as described in Appendix "B".
6.4 The Quality control Supervisor shall route the NCR to the Asst. Vice President - Manager / Fabrication for disposition instructions.
6.4.1 General NCR disposition requirements are as follows:
a) nonconformances are to be dis-positioned in a uniform and timely manner, consistent with the schedule (NCR's not being dispositioned within 30 calendar days shall be brought to the attention of the Quality Assurance Manager);
l b) use-as-is, repair, rework and reject dispositions shall require concurrence by Quality control for adherence to quality requirements prior to implementations
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,y Pr0ctdura SCCP ls.1-2 05/20/77, Rev. 0 THE WALDINGER CORPORAT10N Page 5 of 8 c) dispositiens of Use-As-Is, Repair, Rework and Reject shall require concurrence by client (Engineer) prior to implementation.
6.4.2 The Asst. Vice President - Manager / Fabrication reviews the NCR and makes a use-as-is, repair, rework or reject disposition in accordance with the fellowing.
6.4.2.1 Use-As-Ist l
a) the Asst. Vice President -
Manager / Fabrication records the use-as-is disposition on the NCR form, signs and dates and returns the NCR form to the Quality i
Control Supervisor for
, approval; b) upon approval the Quality Control supervisor routes the NCR to the g
client (engineer) and
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requests approval to use the nonconforming item in its present conditions c) partinent documents, such l
as drawings, reports, etc., required for the use-as-is rationale shall be forwarded to the i
client upon their request; d) when the use-as-is disposition is approved by the client, the Quality control Supervisor forwards the NCR to the Asst. Vice President - Manager / Fabrication for implementation of the dispositions l
e) if the client rejects the use-as-is disposition, the Quality control supervisor submits another method for correcting the nonconforming items; l
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Procedure SCCP 15.1-2 THE WALDINGER CORPORATION 05/20/77, Rev. O Page 6 of 8 f) upon acceptance of the use-as-is disposition, the Quality control Supervisor shall assure l
that the reject cags are l
removed and releases the l
item for use.
6.4.2.2 Repair:
i a) the Asst. Vice President -
Manager / Fabrication records the repair disposition on I
the NCR form, writes instructions at a level of detail sufficient to identify work operations and inspections required to accomplish the repair l
of the itam, attaches any i
drawings, signs and
. forwards the NCR form to the Quality Control l
Supervisor for approval.
Upon approval, the NCR is l
g routed to the client in
/
accordance with Paragraph l
6.4.2.1 b) and c);
b) upon acceptance of the repair disposition by the client, the nonconforming item is released to be repaired, and a copy of the NCR with required engineering documentation is forwarded to the Manager of Fabrication and Delivery; c) once repaired, the Quality control Supervisor inspects the repaired item and if acceptable signs the NCR, removes the reject tags and the item is released for further work.
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6.4.2.3 Reworks a) rework dispositions are processed in accordance l
with the " repair" disposition, Paragraph 6.4.2.2, except that the clients a
e Procedure SQCP 15.1-2 THE WALDINGER CORPORATION 05/20/77, Rev. O Page 7 of 8 approval is not required.
However, these NCR's must be routed to the clien: for notification as these instances occur.
6.4.2.4 Reject:
a) the Asst. Vice President -
Manager / Fabrication records the reject disposition on the NCR form, signs and dates, and forwards to the Quality Control Supervisor for approval; b) the Asst. Vice President -
Manager / Fabrication may scrap or return the item to the supplier.
If a final disposicion of scrap has been made, the NCR shall be forwarded to the client for approval prior to the
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material being scrappedt c) copy of the NCR shall accompany the items being returned to a supplier; d) items dispositioned as scrap shall he' removed from the f ab shop to avoid inadvertant use or installation subsequent to client approval.
6.5 Final acceptance of the NCR will be computed by the Quality Control Supervisor upon review of the completed NCR form.
The NCR log entry shall be closed out in accordance with Appendix "B".
6.6 An NCR may be superseded after an NCR number has been assigned.
The new NCR shall carry the same NCR number with a suffix letter A.,
B.,
etc.
A statement to this effect shall be recorded on the NCR numbers cross-referenced on both the original and the superseding form.
NCR forms containing Rework, Repair, or Use-As-Is dispositions may only be superseded with the approval of the original review personnel.
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l Pro'edure SQCP 15.1-2 THE WALDINGER CORPORATION c
05/20/77, Rev. O Page 8 of 8 l
6.7 If an NCR should become lost, it shall be reissued j
by initiating another form with appropriate cross-l reference to the original.
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6.8 Installation of Monconforming Items l
l 6.8.1 Nonconforming items may be conditionally released to the jobsite for installation l
in permanent plant construction when it is a considered decision by the Material i
Review Board.
Specific written approval from each of the above must be obtained and documented on the NCR along with the basis for the decision to permit installation of the nonconfor=ing item.
Approval te install nonconforming material or equipment shall be given when each of j
the following conditions are mets a) traceability and identification as a nonconforming item are maintained by tagging; b) the nonconforming itam can be removed,or corrected at a later date (prior to use) without damage or contamination to the associated permanent plant equipment or structures; c) the NCR is used to record the conditional release and subsequent reinspection for assuring the retrievability or limiting the use of the nonconforming material or item.
7.0 Records 7.1 Records maintained under this procedure shall include l
a)
Honconformance Report, Form No. QC35/04-02-77 b) l Nonconformance Report Log, Form No. QC36/04-02-77 l
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s MER CORNN Procedure SQCP 15.1-2 05/20/77, Rev. O Page 1 of 4 i
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l APPENDIX "A" i
INSTRUCTIONS FOR PREPARING AND PROCESSING l
TEE NONCONFORMANCE REPORT (NCR) r I
This instruction describes'the actiens required by Cualitf Control Supervisor to assure preper documenatien of ncncenferminq conditions.
The following description of entries are' cress-referenced to the sample form (Figure 1).
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i Entry E!aEhBE
- EE1U, 991911stion I
1 Drawing Number /
En'ter the drawing number of Item or description of the non-l conforming item.
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2 Item Description Enter the drawing number l
cr item name of the non-l l
conforming item in Entry l
No. 1.
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3 Project Number Enter the number of the
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projects:
1.e., W-3, WpS-2, etc. (this may be l
j stamped or proprinted I
,for specific projects).
4 NCR Number Enter the next sequential serial number from the j
NCR Log.
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i 5
Area / Elevation /
Enter the geographical Location / System area, drawing elevation, i
specific location or i
funetional s NOTE:
)
Only one (1)ystem.
i should apply.
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6 Supplier Enter the name of the l
supplier of the item recorded in htry 1 or 2.
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7 Reference Enter the serial number i
DR Number of the Deficiency Report written against the non-r conforming condition, if
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required.
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Monconforming Describe in clear concise l
Condition words the exact noncon-1 forming condition, reference
s Proceduro SCCP 15.1-2 05/20/77, Rev. O THE WALDINGER CORPORATION Page 2 of 4 Entry Number Entry Description client and The Waldinger Ccrporation drawings, specifications or related 2n intering d::crontati:n.
Int:r any additiensi inf:r stien not specifically pr:vided fer er if space is limited in the heading blocks, flagnete as necessary.
9 Reported by/
3ignature and date of the Date Quality control Supervisor or Inspector identifying the nonconforming condition.
10 Dispcsition Define in detail the dis-position required to correct the ncnconfor=anco conditi:n.
11 Material Review Enter an "x" to indicate the Board Concurronce stogcry in which the dis-positions fall; i.e.,
Use-As-Is, Ropair, Rowork, Reject.
12 Project Mgr/
The signature and date of the Asst. VP Mgr.
Project Manager at the jobsite Fab.
or Anst. Vice President /
Manager Fabrication at the fab shop responsible for Use-As-Is, Repair, Re-work and Reject dispositions entered in Block 10.
13 Quality control The signature and date of Supervisor Quality Control Supervisor concurring with the dis-position and/or instructions entered in Block 10.
14 Client The signature and date of the client (engineer) rep-resentatives concurring with the Use-As-Is, Repair and Rework dispositions.
15 Fix Enter a statement of action Accomplished taken to implement the ft::::itien ontored in Diock 10.
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l Procedure SQCP 15.1-2 THE WALDINGER CORPORATION 05/20/77, Rev. O Page 3 of 4 Entry Nu:&er Entry Description 16 Quality control The signature and date of i
Inspector /Date the Quality Control Inspecter signifying the fix acecmplished in Block 15.
17 QC Final The signature and date of the Acceptance Quality Control Supervisor signifying final acceptance.
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l Prac: dura SQCP 19.1 05/20/7.7, Rev. O Page 4 of 4 Appendix "A" cont'd.
NONCONFORMANCE REPORT
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Procedure SQCP 15.1-2 THE WAUNNGER CORPORATION 05/20/77, Rev. O Page 1 of 2 i
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APPENDIX "B" i
INSTRUCTIONS FOR PREPARING AND PROCESSING THE NONCONFORMANCE REPORT LOG (NCRL)
I This Ncnconformance Report Log prcvides a chronoligical listing l
cf valid NCR's initiated at the fab shop. This log shall be l
maintained and controlled by the Quality Control Department.
The following description of entries are cross-referenced to the l
sample form (Figure 1).
Entry i
Number Entry Description l
1 NCR Number Enter the next sequential NCR report serial number.
2 Date Written Enter the date the QC Super-visor reviews and signs the l
nonconformance reported in block 9 of the NCR form.
)
3 Drawing No./
Enter the drawing number of Item item description as recorded in block 1 of the NCR form.
4 Area / Elevation /
Enter the area / elevation /
location / system location / system as recorded in block 5 of the NCR form.
5 Date Closed Enter the accepted by date as recorded in block 17 of the NCR form.
6 Remarks Enter any pertinent infor-nation relative to the NCR.
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Procedure SOCP 15.1-2 Page 2 of 2 05/20/77, Rev. O nppendix "B" Con't.
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NONCONFORMANCE REPORT LOG....
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