ML20248G081
| ML20248G081 | |
| Person / Time | |
|---|---|
| Site: | 07100111 |
| Issue date: | 06/30/1987 |
| From: | MATERIALS TESTING LABORATORY, INC. |
| To: | |
| Shared Package | |
| ML20248G066 | List: |
| References | |
| NUDOCS 8910100051 | |
| Download: ML20248G081 (77) | |
Text
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v MATERIAL J.
7 "ESTING lLABORA"0 RIES o
0"JALI"Y ASS""RANCE MAN JA" l4 REVISED "UNE,1987 p"88ar518sbj
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Table of Contents Section No.
~1.
Foreword 1-1
.-i 2.-
Organization Structure and Responsibility' 2-1 3.
Personnel Qualification 3-1 4..
Equipment Calibration 4-1 5.
Customer Evaluation 5 -l' i
6.
Customer Review and. Planning 6-1 L.!
7.
Process Control 7-1 8.
Alternative Inspection Provisions and Approval
'j Request L8-1 9,
Purchasing 9.-l' 10.
Receiving Inspection 10-11 11.
Storage, Handling, and Delivery 11-1 j
12..' Documentation, Drawing, and Change' Control 12-1 i
d 13.
Sampling Inspection 13-1 14.
Inpsection and Testing 14-1 15.
Nonconforming Materials 15-1 g
i 16.
Corrective Action 16 '
17.
Records 17-1 l
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.D MTL MANUAL / PROCEDURE DISTRIBUTION RECORD MANUAL ISSUED TO DATE NUMBER ISSUED 1
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MTL Procedure 01 - FOREWORD h
1.0 Material Testing Laboratories Inc.,
hereafter referred to as MTL, is an independent testing laboratory located in Norfolk, Virginia.
The services provided by MTL include:
1.1 Non-destructive testing:
1.1.1 X-ray and gamma radiography 1.1.2 Magnetic particle testing 1.1.3 Liquid penetrant testing 1.1.4 Ultrasonic testing 1.1.5 Eddy Current testing 1.2 Mechanical testing 1.2.1 Tension testing o
UN 1.2.2 Compression testing 1.2.3 Bend testing 1.2.4 Impact testing 1.2.5 Hardness testing 1.3 Chemical analysis 1.3.1 Atomic absorption 1.3.2 Emission spectroscopy 1.3.3 Carbon analysis 1.3.4 Sulfur analysis l
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1.4 Metalographic interpretation
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.l.4.1 Sample preparation 1.4.2 Examination for decarburization 1.4.3-Examination for carburization (case depth) 1.4.4
~ Inclusion count, grain size estimate 1.4.5 General structure l
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2.0 MTL Quality-Assurance Manual, Procedures and Documentation II
'I are developed to comply with MIL-I-45203, FAR Clauses, ANSI I
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N45.2, 10 CFR 50 (app. B) NDA 3900 and customer specifications, codes, and documents, as revised or. amended I
which require inspection systems'cn: procedures defining inspections, tests, or operations to be performed.
3.0 This manual defines an effectively controlled inspection
-1 system to assure that MTL's (or it's vendors') inspection system, as applicable:
3.3 Covers all supplies or services provided and complies with customer order requirements.
3.2 Is properly documented, including, as applicable, specific inspection proce'dures.
Gh 3.3 Covers all required inspections and tests.
3 3.4 Is available for review or approval of the customer, or it's representative, in accordance with customer order requirements.
3.5 Is properly reviewed, revised, or changed and submitted for review of the customer in accordance with order requirements.
4.0 MTL's Quality Assurance Manual, Procedures and Documentation shall be reviewed by the President of MTL, or his authorized representative, hereafter re-ferred to as POR, and necessary revisions or changes f
made whenever required by customer order, specifications or documentation referenced therein.
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4.1 When' required by customer order, or applicable
. *I documentation referenced therein, additional procedures and documentation shall be developed defining inspection methods, techniques and equipment to be employed in controlling the inspection or test to be performed.
4.2 MTL's Quality Assurance Manual, Procedures and Documentation defined herein shall be available to the customer, or it's representative, for evaluation to determine compliance with customer order requirements.
5.0 Formal revisions or permanent changes to MTL's Quality Assurance Manual, Procedures and Documentation defined herein shall not be made until they are reviewed by the
]g customer, as required, and the POR.
6.0 Requests or suggestions for revisions, changes, or improvements of MTL's Quality Assurance Manual, Procedures and Documentation shall be submitted to the President of MTL.
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MTL PROCEDURE.02 - ORGANIZATION STRUCTURE AND RESPONSIBILITY 2h l.0 The overall responsibility for the development and implementation of this Quality Assurance Manual, Procedures, and Documentation defined herein, is vested in the President of MTL or other designated corporate officer.
1.1 The POR shall assure that MTL personnel performing assigned functions, tasks, or inspections have sufficient authority, responsibility, and training to perform assigned duties or operations.
1.2 Should conflicts exist between personnel, departments within MTL, the customer, or the customer's representative, the President of MTL shall assure that the conflict or problem is resolved.
S 2.0 The attached organization chart establishes MTL's j
-organizational structure, levels of responsibility, and i
reporting structure.
3.0 The organizational structure and functional responsibility assignments shall be such that attainment of quality l
objectives is accomplished by MTL personnel who have been assigned or delegated responsibility for performing operations, inspections and tests.
3.1 verification of compliance to established customer requirements shall be accomplished by qualified MTL personnel who have direct responsibility for performing assigned work.
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4.0 The MTL personnel identified below are designated as points of contact for the customer, or the customer's representative.
In addition, personnel identified shall be responsible for the functions delineated.
4.1 The President, Directors of NDT and Laboratory Operations Analytical, Chemist and designated Level III's shall be responsible.for assuring compliance with established customer requirements in accordance with instructions contained herein.
5.0 When required by customer order, the POR shall submit a letter to designated customer representative identifying points of contact listed above and MTL personnel qualified to perform inspections and tests specified by customer order.
' g 5.1 A copy of the letter initiated shall be filed in each customer order file, as applicable.
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MTL PROCEDURE 03 - PERSONNEL QUALIFICATION bh 1.0 All non-destructive testing personnel employed by MTL shall be qualified in accordance with SNT-TC-1A, MIL-STD-410D, and MIL-STD-271E as set forth in this written practice.
Candidates considered for employment at MTL shall prepare a MTL Personnel Resume to aid the responsible designated Level III in evaluation of the candidates' education and work experience factors necessary to satisfy the requirements of this procedure.
1.1 The POR shall initiate a personnel file folder for each candidate hired by MTL.
The file shall be filed in a section titled " Qualified Personnel Records".
1.2 Each individual's file shall be' identified with personnel name and-filed.
The file initiated shall contain, as g
applicable, but not be limited to:
1.
MTL Personnel Resume 2.
MTL Personnel Certification Record 3.
MTL Personnel Physical Examination Record 4.
MTL Examination and Test Summary 5.
General, specific, and practical test and examinations 6.
Other suitable evidence of satisfactory qualification 1
when such qualifications are used in lieu of
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examinations
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Additional information considered essential.
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- 2;0- MTL's NDT Qualification and-Certification Written Practice E
i has'been developed _to assure personnel performing operations, inspections, and tests have sufficient education, training, and experience necessary to assure n,.
complete understanding of NDT methods, principles, and procedures-for which they are certified.. To be considered' for certification at MTL, candidates shall receive or have sufficient' knowledge or training for initial qualification to Level I or Level II.
The necessary education and work experience is-specified by the following table:
ET-LEVEL I
II I II I II I II I II
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College (2 yrs.)-with passing grade '12 40 8
4 24 40 4
4 8
8 in engineering or science, college or technical ~ school fh (Training Hours Required) t L
High School. Graduate /GED 20 40 12 8 40'40 4
8 12 8 L
(Training Hours Required) l Educational Levels Listed 3
9 13 3
9 1
2 19 l
(Work Experience in. Months) 2.1 MTL personnel shall be qualified in one or more of the l
following four basic levels as follows:
1.
TRAINEE - Prior to being qualified and certified Level 1, candidate shall be considered a trainee.
Trainees shall work with qualified and certified Level II or III personnel.
Candidates in this classification shall not be permitted to work independently, conduct tests, interpret or evaluate results of tests or report test results.
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2.
Level I - Personnel in this classification shall-be-qualified to perform specific calibrations, tests, and evaluations for acceptance or rejection 1
of materials under test according to established MTL procedures and to record results.
3.
LEVEL II - Personnel in this classification shall be qualified to set up and calibrate equipment and evaluate results of tests in accordance with applicable documentation defined by MTL NDT inspection records; be knowledgeable of NDT methods and limitations for which qualified; be capable to train NDT Level I personnel; and be capable of preparing written instructions and reporting of test results.
hI A.
Personnel may be certified directly to MTL j
Level II without any time at a lower level, if the candidate has the required experience consisting of the sum of time required for Level I and II at some other facility, if the i
requirements of this written practice are 1
complied with, and if the candidate:
1.
Has proof of prior certification l
2.
Was working in the capacity to which he certified within the last six months prior to employment at MTL.
I 3.
Is decertified within six months after
(}j termination from another facility.
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NDT LEVEL III - Personnel in this classification shall be capable of establishing techniques and procedures; interpreting applicable documentation and designating methods, techniques, and procedures to be used during inspection; and shall have sufficient knowledge of materials, fabrication, and product technology necessary to establish techniques and provide assistance in establishing acceptance and rejection criteria.
He shall be capable of training Trainees, Level I and Level II.
He shall possess a general knowledge of other NDT methods, and be capable of establishing training programs, developing written ex'aminations, selecting samples to be utilized during tests, and insuring compliance with established MTL procedures and requirements therein.
A.
MTL may waive examination for NDT personnel designated Level III based upon their ability, achievement, experience, and education.
B.
Records and documentation shall be on file for each designated Level III qualified in this manner.
The president of MTL shall issue a letter of authorization authorizing designated personnel to act as an MTL Level III.
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w 3.0 To be considered for certification by MTL, candidates shall M-
'be' required to demonstrate their understanding of NDT principles, methods, and procedures by passing examinations to verify their physical and technical qualification.
The examinations to verify physical and technical qualification shall consist of the following:
3.1 Physical Examination 1.
Candidates shall be required to pass a vision test at the time of qualification.
The vision test shall be conducted by a qualified technician utilizing standard test methods for determining visual acuity.
The standard of acceptance for vision test shall be' natural or corrected near distance acuity such that the candidate is capable' 3
of reading J-1 letters on the standard Jaegar's Test Type Chart for near vision or equivalent type test (i.e. the ability to perceive an ortho-rater minimum of 8 or similar test pattern is also acceptable).
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Candidates shall be able to distinguish between i
colors, if required by assignment of work.
3.
Candidates for assignment in radiographic inspection shall be tested for brightness discrimination, using radiographs containing randomly distributed penetrametors and indications of various densities and sizes.
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'The POR shall initiato a MTL Personnel Physical hh Examination Record which indicates which test was administered to employee.and indicates the 1
results.
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The physical examination record shall be i
maintained in each individual's personnel file.
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Unless otherwise specified, MTL personnel up to and including age 35 shall have a vision test administered annually; above 35 j
semi-annually.
Corrective aids used during this physical examination shall be noted on 1
applicable MTL r'ecords and shall be required I
for future examinations, inspections and
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tests.
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Should customer order, or applicable 1
i documentation, require physical examinations more frequently than specified in paragraph B j
above, MTL personnel shall be tested and retested according to those requirements.
MTL records shall be noted accordingly.
5.
The POR shall check the Physical Examination l
Record in each employee's record each month to
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determine if he is due for vision examination.
He f
i shall enter a record of his review on a Log Data j
1 Record form which shall be kept in the personnel l
records file.
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h 3.2 When required, the responsible Level III (or authorized personnel) shall administer the training programs contained-herein and conduct written examinations in l
accordance with the following:
'1.
The Iavel III.shall prepare a written general examination by selecting test questions covering NDT test raathod from appropriate ASNT question booklets.
A.
The minimum number of questions for Level I or II shall be:
TEST METHOD NUMBER OF QUESTIONS
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Radiographic 40 j
Magnetic Particle 30
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~l Ultrasonic Testing 40 n.1 Liquid Penetrant 30
j Eddy Current B.
The written general examination shall be j
i conducted without access to reference i
material, training documentation or other l
l material /information.
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The Level III shall prepare a written specific examination by selecting test questions covering l
l the test method, equipment or materials utilized, procedures and test techniques from applicable 1
documentation, specifications, codes and acceptance gg criteria utilized by MTL in their NDT procedures.
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'The minimum number of questions for Level I and II shall be:
TEST METHOD NUMBER OF QUESTIONS Radiographic 30 Magnetic Particle 20 Ultrasonic Testing 20 Liquid Penetrant 2n Eddy Current 20 B.
The written-specific examination shall be conducted with access to reference data, specifications, codes, notes, reference material, training program outlines and other information provided'during indoctrination and training.
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The Level III shall select and approve one sample which the candidate must analyze during the practical examination.
A.
To be considered for Level I certification, the candidate must analyze and demonstrate the ability to perform the required NDT method in accordance with MTL established procedures.
B.
To be considered for Level II certification, the candidate must analyze and demonstrate the ability to perform applicable NDT test, interpret and evaluate the results.
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The Level.III, or authorized personnel, shall be responsible for grading and documenting NDT examinations in accordance with the following:
A.
The final examinations, general, specific and practical, shall cach be worth 100 points each.
To be certified Level I or II, the candidate must have an average composite score of 80 (i.e. General + Specific + Practical divided by 3 = 80% or better).
No test score shall be less than 70% on any one examination.
Candidates failing to attain the required examination grades shall receive additional training as determine'd by the Level III and retested within 30 days.
' $h B.
The Level III shall witness candidates performing the required NDT inspection during practical examinations and shall verify at least 10 different checkpoints requiring a complete understanding of test variables and procedure requirements.
1.
The Level III shall prepare a MTL Level III practical examination verification and identify test variables and i
procedural requirements the candidate E
performed correctly or incorrectly.
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The Level III shall initiate and complete a C.
MTL " Examination and Test Summary" identifying personnel, results, and other information specified.
1.
The " Examination and Test Summary" shall be attached to the written examinations and practical examination verification l
record and be filed in each individual's i
personnel file.
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The Level III shall initiate and complete a MTL " Personnel Certification Record" for each t
candidate to evidence compliance with-l established requirements of this written j
practice and applicable qualification specifications.
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The " Personnel Certification Record" shall be filed in each individual's personnel file.
4.0 NDT Personnel shall be requalified in accordance with the
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following provisions:
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4.1 At three year intervals from the date of initial
)
qualification, the Level III shall administer l
l examinations in accordance with the procedures l
I established by this written practice.
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4.2 If NDT personnel has not been actively engaged in nondestructive testing for a period of six months.
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4.3 If the Level III has reason to believe that NDT personnel assigned is unable to competently perform the' NDT level to which he-is qualified.
4.4 The POR shall review all MTL Certification Records each month to determine if any personnel are due for recortification.
He shall note this review on an MTL Log Data Record to be kept.in the personnel records file.
5.0 Records shall be initiated, maintained and. filed in accordance with instructions contained herein or quality assurance procedures referenced.
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MJsTERIAL TESTING LABORATORY OF VIRGINIA EXAMINATION AND TEST
SUMMARY
PERSONNEL NAME NDT METHOD EXAMINATION DATE ADMINISTERED BY SCORE GENERAL SPECIFIC PRACTICAL COMPOSITE AVERAGE 7p REVIEWED BY DATE c5 4,3F APPROVED BY DATE-t I
QUALIFICATION LEVEL
( )
LEVEL I 1
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LEVEL II l
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LEVEL III l
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h PERSONNEL INFORMATION RESUME
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NAME:
PLACE OF BIRTH DATE SOCIAL SECURITY NUMBER HOME ADDRESS PHONE EDUCATION COLLEGE MAJOR MINOR YEARS COMPLETED FROM TO OTHER:
h HIGH SCHOOL YEARS COMPLETED FROM TO JOB RELATED PROGRAMS OR TRAINING PROGRAMS COMPLETED DESCRIPTION NUMBER OF HOURS YEARS l
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'p CAREER EXPERIENCE (PRESENT - BACK)
FROM TO lCOMPANYNAMEANDDESCRIPTIONOFRESPONSIBILITIES AWARDS RECEIVED COMMITTEES (RELATED TO POSITION)-
D COMMUNITY SERVICES l
PERSONAL INTERESTS f
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4-l MTL LOG DATA RECORD YEAR MONTH REVIEWED BY' DATE N
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MTL PERSONNEL PHYSICAL EXAMINATION RECORD PERSONNEL NAME:
VISION TESTS DISPOSITION TECHNICIAN DATE PASS FAIL
( ) VISUAL ACUITY
( ) COLOR TEST
( ) BRIGHTNESS DISCRIMINATICM
( ) CORRECTIVE AIDS REQUIRED
( ) YES ( ) NO TYPE:
( ) VISUAL ACUITY
( ) COLOR TEST
( ) BRIGHTNESS DISCRIMINATION
( ) CORRECTIVE AIDS REQUIRED
( ) YES ( ) NO TYPE:
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( ) VISUAL ACUIIT
( ) COLOR TEST l
( ) BIRGHTNESS DISCRIMINATION
( ) CORRECTIVE AIDS REQUIRED
( ) YES { ) NO TYPE:
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q u9 MTL PERSONNEL RECALL RECORD L:
L PERSONNEL NAME:
NDT METHOD:
CERTIFICATION COMMENTS DATE DUE DATE i
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MTL PROCEDURE 04 - EQUIPMENT CALIBRATION 1.0 calibration of measuring and test equipment shall be accomplished in accordance with manufacturer's recommendation or published standard methods not be available, the POR shall prepare written procedures procedures defining calibration of measuring and test equipment for those devices calibrated by MTL personnel.
1.1 Calibration procedures developed, manufacturers' recommendations or standard methods, utilized by MTL personnel shall be identified on a Calibration Procedures Index.
MTL calibration procedures shall be designated by calibration procedures numbers.
l.2 The POR shall initiate an MTL Calibration Record for b
each piece of measuring and test equipment calibrated l
by MTL personnel.
1 1.3 Records relating to calibrations performed shall be maintained in a file section titled " Calibrated l
L Equipment Records".
1.4 The POR shall initiate a " Calibrated Equipsient Recall
,;f Card" for measurement standards and each piece of l
measuring and test equipment to control the recall of equipment requiring calibration and to demonstrate compliance of recalibration at established intervals.
I 1.
The Calibration Recall Card shall be filed in a l
file box titled "Rocall Records" according to calibration due date (i.e. month / year).
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2.
The POR-'shall review the recall cards on the
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first working day of each month to identify-
- equipment due.for calibration and sign the
" Calibration Record Log" to-evidence his review.-
.A.
-The " Calibration, Record Log" shall be l
maintained and~ filed.in the front of the recall records. file box.
3.-
The POR shall be responsible for~ removing Aj equipment identified.from service prior.
j to calibration due date.
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i 1.5 The POR shall initiate and maintain a "Me'asurement L
Standards and Equipment Index" tof dentify and.
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control measurement standa'rds (both reference'and transfer),' measuring and test equipment to be utilized during inspection or testing, and to i
identify equipment requiring calibration.
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- 2.0 Subcontracted calibration services for measurement standards, measuring and test equipment shall be
_ performed by the manufacturer or commercial facility j
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utilizing standards that are traceable to the NBS'
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L 2.1 Calibration sources other than the manufacturer, i
government laboratory, or the NBS, shall be audited 1
by the POR utilizing a vendor audit checklist prepared l
from the requirements of MIL-STD. 45662 or related l
i l6-documentation.
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Records of audits performed shall be maintained in c
~hh a file.section-titled " Audited Calibration Sources".
?2.
A' file shall be initiated-for each audited: source I
L and shall'be filed alphabetically by vendor name.
i 2.2 Should the vendor have all documentation, procedures, l
records-and equipment'necessary tofperform L
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subcontracted. services,'the POR shall issue a
o letter of approval to'the audited vendor along with
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-a copy ofEthe completed audit checklist.
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Should the vendor not have all documentation, H
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l procedures, records'or equipment'necessary/to perform subcontracted services, the POR shall a
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request Corrective Action in accordance with-g l
Quality Assurance Procedure, MTL Procedure' j
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2.3 The calibration source shall be required to provide
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records, reports, certificates, or data sheets
-I attesting to the date of calibration, calibration j
source, accuracy and conditions under which calibration results were obtained.
3.0 Measurement standards, measuring, and test equipment shall l
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L 3.1 Calibrated in an environment controlled to the extent necessary to assure continued measurements of required-l accuracy giving consideration to temperature, l
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cleanliness, and other controllable factors affecting l
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measurement accuracy.
$"D 3.2 Calibrated at periodic intervals based upon stability, purpose, degree of usage and accuracy required.
Calibration intervals for measurement standards, measuring and test equipment shall be designated on the " Measuring Standards and Equipment Index".
1.
Calibration intervals shall be shortened or lengthened by evaluation of the results of previous calibrations and adjusting the calibration schedule to reflect findings.
The evaluation performed must provide assurance that calibration interval adjustments will not adversely affect the accuracy of
]g measurement standards, measuriug and test equipment.
If evaluation of calibration data indicates that the measurement standard, measuring and test equipment is not within established tolerances, the recalibration interval shall be reduced by one-half (1/2).
If equipment is within established tolerance after three (3) successive calibrations, the recalibration intervals shall be doubled.
3.3 Calibrated against standards that have an accuracy value of four (4) to ten (10) times the accui:acy of equipment being calibrated.
f) 3.4 Labeled with a calibration label to indicate the l
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I calibration date, due date, and by whom equipment
- h was calibrated.
1.
When labeling is not practical, due to the functional characteristics of equipment, an identifying number shall be vibroctched or stamped in a nonworking area.
The identification number assigned will be recorded on applicable documentation.
2.
Inspection and ',est equipment which does not-require calibration shall be labeled or L
vibroetched "NCR" to indicate no calibration is required.
3.
Inspection and test e'quipment, which requires
.g calibration prior to use, shall be labeled
" CPU" to indicate that this device must be l
calibrated prior to use.
,3 A.
Measuring and test equipment requiring calibration prior to use shall have a log book near each de~ ice to record each v
calibration performed, or calibration may be noted on the report of the inspection for which the equipment was calibrated in lieu of keeping a log.
B.
Personnel performing calibrations shall enter the calibration date, calibration results, and calibrated by.
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'3.5-Remov'ed from service.when' equipment-becomes damaged,-
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obsolete, or otherwise-inaccurate when first detected:
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Each piece of equipment shall be removed from service and tagged with'a nonconforming material j
1 label.
The exact deficiency, date removed from j
service and additional information considered 0
essential shall be entered on' applicable l
Calibration Record.
2.
Defective, damaged, obsolete, or otherwise inaccurate equipment'shall be segregated from other calibrated. equipment.
3.
Defective,' damaged, o'bsolete, or otherwise inaccurate equipment shall-be repaired, returned to manufacturer, or disposed of by
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authorized personnel.
4.
Equipment disposition shall be recorded on.
applicable calibration records.
4.0 Only measurement standards, measuring and test equipment
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I which have been calibrated'and maintained in accordance rl with instructions contained herein will be utilized to determine the quality of supplies or services provided.
No employee tools shall be utilized for final inspection andL acceptance of supplies unless they are calibrated and maintained in accordance with instructions contained herein.
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o 4.1 - Should out of tolerance conditions exist during initial
! T' calibration or recalibration of MTL measuring or test l
equipment, the calibrating activity shall be required to notify the Laboratory Manager who shall evaluate l-the out of tolerance' condition and determine the action l
to be taken.
1.
Should the out of tolerance condition have an I
l affect on services provided, the Laboratory Manager shall notify customer or customers, as necessary, of non-conforming services provided.
4.2 The Laboratory Manager shall evaluate the adequacy of MTL's calibration in relat'ionship to the out of q
l tolerance condition determined during calibration.
The Laboratory Manager shall adjust calibration intervals in accordance with instructions contained herein and shall determine the adequacy of measuring and test equipment and procedures affected.
5.0 Records shall be initiated, distributed, and filed in accordance with instructions contained herein or Quality Assurance Procedures referenced.
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MTL CALIBRATION SERVICES AUDIT CHECKLIST 1
l VENDOR ADDRESS PHONE I
i VENDOR PERSONNEL CONTACTED DURING AUDIT POSITION SERVICES PERFORMED IN ACCORDANCE WITH ( ) MIL-STD-45662 ( )
( ) CALIBRATION OF MEASUREMENT STANDARDS ( ) REFERENCE i
( ) TRANSFER.
( ) CALIBRATION OF MEASURING AND TEST EQUIPMENT EQUIPMENT LIST VENDOR PROCEDURE NUMBER /
REVISION /DATE/ TITLE l
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l AUDITED BY DATE COMMENTS / NOTES / RECOMMENDATIONS l
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4-MTL CALIBRATION PROCEDURES INDEX l
PROCEDURE NUMBER PROCEDURE TITLE REVISION CHANGE DATE l-
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M MATERIAL TESTING LABORATORIES.OF VIRGINIA, INC.
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Calibration Procedure I-Dat'e Due Date Inspector lDate Duc Date Calibrated Calibrated Inspection l
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. Calibrated Equipment Recall Card l
Equipment:
Ser. No.
Due Calib.
Calibrated by Comments l
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L Calibration Record Log 1984 date by 1985 date by 1986 date by July Apr.
Jan.
Aug.
May Feb.
l Sept.
Jun.
Mar.
Oct.
July Apr.
Nov.-
Aug.
May Doc.
Sept.
Jun.
1985 Oct.
July Jan.
Nov.
Aug.
Feb.
Dec.
Sept.
Mar.
Oct.
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l MTL MEASUREMENT STANDARDS AND EQUIPMENT INDEX l
THE MEASUREMENT STANDARDS, BOTH REFERENCE AND TRANSFER, MEASURING AND TEST EQUIPMENT IDENTIFIED BY THIS INDEX IS 1
l TO BE CONTROLLED IN ACCORDANCE WITH MTL QAULITY ASSURANCE I
PROCEDURE TITLE " CALIBRATION".
ONLY EQUIPMENT LISTED SHALL I
BE UTILIZED TO DETERMINE PRODUCT QUALITY l
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l MTL PROCEDURE 05 - CUSTOMER EVALUATION 1.0 MTL shall permit the customer, or customer's representative, to make all necessary evaluations and verifications to verify inspection system effectiveness in supporting the quality and inspection requirements established by the l
customer order and documentation referenced therein.
2.0 MTL personnel shall extend to the customer their full cooperation and assistance, as required, for their evaluation of MTL Quality Assurance Manual, Procedures and Documentation defined herein.
3.0 Should the customer, or customer's representative, detect inadequate quality provisions, procedures or documentation necessary for the control of qu'ality and compliance with I
customer order requirements, it is requested that the POR I
l be advised in writing of customer findings or deficiencies.
l 4.0 Upon rectipt of written notification from the customer, or l
their representative, the POR shall initiate immediate corrective action in accordance with MTL Quality Assurance Procedure, MTL PROCEDURE 16, titled " CORRECTIVE ACTION".
5.0 MTL shall maintain records of customer evaluations or audits in file section titled "Custo:ner Evaluations".
5.1 A file shall be maintained for each customer performing an evaluation or audit at MTL.
The file shall be identified by the customer's name and filed alphabetically.
5.2 The file shall contain, as applicable, but not limited ar) to:
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1.
Customer evaluation or audit checklist
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2.
Customer corrective action requests l
3.
MTL corrective action replies 4.
Customer approvals l'
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Additional records or correspondence generated 1
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O' MTL PROCEDURE 06.- CUSTOMER ORDER REVIEW l.0 Upon receipt of a customer order, the POR shall initiate l
a'MTL Work Order to identify the scope of work to be performed, inspections and tests required, applicable L
documentation and acceptance criteria.
2.0 A work order number shall be assigned by the POR.
Work Order numbers shall be assigned in ascending numerical order.
Each Work Order shall be logged in the Work I
Order Book maintained by the PCR.
The Work Order Book p
shall show customer.name, type of work, purchase order number, quoted price, and, upon completion of work, the MTL Invoice number used for billing.
3.0 Should there be any changes in'the scope of work effecting the time or additional cost to the customer, the POR shall h
reject the customer order and obtain customer approval of the changes and additional cost prior to scheduling of work.
4.0 Upon approval of the customer order, the POR shall initiate l
an order file identified with the customer's name, order l
j number and MTL work order number assigned.
l 4.1 The customer order file shall contain, as applicable, but not be limited to:
1.
Customer Order l
2.
Modifications or change orders i
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Documentation provided by customer applicable j
rg-p-ex to work performed (DWG, etc.)
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MTL documentation generated by applicable quality assurance procedures i
5.
Additional documentation or records generated I
j 5.0 MTL shall maintain records of customer order review and l
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planning functions in each customer order file developed.
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5.1 Each customer order shall be assigned an MTL Work i
Order number (100, 101, 102, etc.).
All documentation, records, and correspondence initiated shall be controlled by the work order number assigned and i
j shall be maintained in the customer order file I
developed.
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.l MTL PROCEDURE 07 - PROCESS CONTROL l
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i l.0 During initial review of customer orders, the POR shall identify the special process (es) to be performed by MTL i
l-l personnel or vendors, including procedure submission and approval requirements.
1.1 The POR shall prepare written procedures for special l
processes, operations, inspections, or tests performed l
by personnel in accordance with specifications or related instructions applicable to materials or l
l services procured by the customer.
1.
MTL Procedures developed shall be identified on the attached Special Process Procedures Index.
I Procedures shall be designated by special process
<2g procedure numbers (i.e. MTL Process Procedure 7-01 G1 j
Radiography (ASME) ).
l 2.
Procedures developed shall be filed in a notebook 1
1 titled "Special Process Procedures".
l.2 Personnel or equipment shall be qualified or certified in accordance with requirements designated by customer order, specifications, or related instructions prior to i
the performance of work.
I 1.
Records, reports, certificates, or data sheets shall be maintained attesting to the date, 1
inspections, tests and conditions under which l
personnel and equipment were qualified or certified.
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2.0 Special processes defining' operations, inspections, tests,.
3 or. work' performed shall be identified and inspected'in
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L accordance with Quality Assurance Procedure, MTL 1
L PROCEDURE 14, titled " Inspection and Testing".
3.0 When' required by customer order, copies of MTL procedures 5
shall be submitted for information, review and/or approval.
The POR shall prepare and attach a procedure approval iequest documentation package and forward to designated customer representative for their j
information, review, or approval.
This shall be done in accordance with Quality Assurance Procedure, MTL I
PROCEDURE 08, titled " Alternative Inspection Provisions.
l and Approval Requests".
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MTL shall not proceed with special processes, operations, j
4.0 inspections, tests, or work until receiving approval of the customer, or customer's representative, for procedure (s) submitted for approval.
4.1-Should the procedure (s) submitted to the customer be j
i conditionally approved or disapproved, the POR shall initiate corrective action in accordance with Quality I
Assurance Procedure, MTL PROCEDURE 16, titled
" Corrective Action".
1.
Revisions or changes to procedures shall be i
processed in the same manner as the original I
document.
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- 5. 0 ' ' Records shall be initiated, distributed, and filed in accordance with instructions contained herein or 1
quality-assurance procedures referenced.
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MTL'SPECIAL PROCESS PROCEDURES INDEX l
I PROCEDURE TITLE REVISION CHANGE DATE l'
NUMBER-l l
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) ~4 MTL PROCEDURE 08 ALTERNATIVE INSPECTION PROVISIONS AND l $
APPROVAL REQUEST I
1.0 Should.MTL elect to use equipment or procedures other than l
those specified or. referenced by the customer order, the POR I
shall assure that such equipment or procedures shall provide, as a minimum, the quality assurance required by l
customer order.
1 l
2.0 The POR shall evaluate and demonstrate the effectiveness of each proposed alternative equipment and procedure for the customer or their representative.
In addition, the POR shall provide information necessary to assure each alternative inspection device or procedure is at least equal to or better than those s'pecified by customer order.
Sg 3.0 Whenever the customer has retained authority to approve MTL inspection procedures or equipment, the POR shall initiate a
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" Procedure Approval Request" to obtain customer approval l
prior to.use.
Should the customer be a government agency, j
the request shall be forwarded to the Procurement Contracting Officer via the representative assigned inspection responsibilities at MTL.
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f 3.1- ' The'" Procedure: Approval Request" shall include,'as' iq.
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applicable,:but not be limited to:
1.
' customer order and references:
- 2.
MTL data and references-3.
Documentation, operation,' inspection, test equipment, or procedures requiring. approval.
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- 4.
Additional information considered essential.-
3.2 Should:the approval request be' issued'for an l
alternative inspection device or procedure, MTL shall" continue to use the original' device or.
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procedure required by the customer order until1
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receiving approval to use proposed alternative.
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!, y' 4.0 Unless otherwise.specified, one original and one copy of each " Procedure Approval Request" initiated shall be
-forwarded to the customer or the Procurement Contracting officer-, or their designated representative, for their 1
information, review, and approval.
4.1-One copy of each request shall be retained in the customer order file pending receipt of customer approval or disapproval.
Upon receipt of customer disposition, the file copy shall be destroyed and replaced with copy signed by customer representative.
5.0 Records shall be initiated, distributed, and maintained in accordance with instructions contained herein.
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MTL PROCEDURE APPROVAL REQUEST l
l l-FROM:
TO:
I WORK ORDER NO.
CUSTOMER ORDER NO.
SUBMITTAL DATA PROCEDURE, OPERATION, INSPECTION, TEST, OR EQUIPMENT REQUIRING l
APPROVAL SUBMITTAL DUE DATE SUBMITTAL DATE SUBMITTED BY The attached documentation is submitted for your ( )
g information ( ) review ( ) approval in accordance with J
the requirements of Customer Order No.
Should the attached documentation not be in accordance with the requirements of please identify deficiencies and provide proper reference to applicable specification.
DEFICIENCIES SPECIFICATION REFEREN IT IS REQUESTED THAT THE CUSTOMER INDICATE THEIR DISPOSITION I THE CUSTOMER DISPOSITION BLOCK BELOW FOR MTLV FUTURE REFEREN CUSTOMER DISPOSITION OF MTLV DOCUMENTATION MTLV DATA
( ) APPROVED ( ) CONDITIONAL APPROVAL DATE RECEIVED
( ) REJECTED ( )
CAR REQUIRED ( )
DISPOSITION BY COMMENTS DATE:
. 9 e-l MTL PROCEDURE'09 - PURCHASING L*
l.0 The POR shall review customer orders, specifications, and j
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supplies or services procured by MTL.
2.0 The POR shall initiate verbal or written purchase orders which identify requirements applicable to supplies or l
services procured.
When laboratory gasses, test materials
- j l
l such as liquid penetrants, and other materials are ordered 1
which must meet definite specifications and have l
certification papers a written purchase order or written blanket purchase order to the supplier shall be used l
designating specifications which must met.
I 3.0 When written purchsse orders are issued copies shall be l
g retained in purchase order book in numerical order, pending receipt of supplies or services procured.
l 4.0 Procured supplies or services shall be subjected to l
receiving inspection in accordance with Quality Assurance
)
l Procedure, MTL PROCEDURE 10, titled " Receipt Inspection".
l 4.0 Written MTL purchase orders shall specify customer source
. 4 inspection only when specified by customer order or 1
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customer's representative.
' I Records shall be initiated, maintained, and distributed in.
5.0 j
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accordance with instructions contained herein and Quality i
Assurance Procedures referenced.
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MTL PROCEDURE 10 - RECEIPT INSPECTION i
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1.0 Upon receipt of customer' furnished, LEVEL I, or Controlled material, MTL personnel shall prepare a MTL Work Order to follow the item, container, or pallet, as applicable.
l.1' The item, container, or pallet shall be moved to a f
L designated area for 3..aterial awaiting inspection.
The POR shall review the yellow copy of the work order and
.i 2.0 1
forward it to the assigned inspector for performance of the task.
Inspection of customer owned or furnished material 2.1 l
shall include, as applicable, but not be limited to:
1.
Verification of quantity records 2.
Examination of materials to detect damage in transit
)
3.
Inspection for identification, completeness, proper type or configuration I
4.
Verify functional testing, if required by customer 5.
Periodic inspection during processing or storage-l 1
to guard against damage from handling and l
deterioration during storage.
l 6.
Verify items are properly identified and i
protected from improper use or disposition
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Should materials received be damaged or unacceptable for testing, the pOR shall initiate a "MTL Damaged or Defective Material Report" defining deficiencies and requesting material disposition.-
7.
The Receiving Inspection Record and Defective l
Material Report (when issued) shall be filed in the customer order file.
A.
Should the customer be a government agency, the Defective Material Report shall be forwarded to the local representative assigned inspection responsibilities at I
MTL with a request that he verify findings.
B.
A copy of the report shall be forwarded to g
the procurement Contracting Officer or customer personnel designated by the order.
2.2 Inspection of MTL procured supplies or services shall d
include, as applicable, but not be limited to l
1.
Review of documentation to verify compliance with MTL purchase order requirements 2.
Verification of quantity records 3.
Inspection for damage during transit i
4.
Verification of supplies or services received (identification, type, etc.)
5.
Additional inspections deemed necessary to verify compliance with MTL requirements.
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6.
Report initiation and distribution.
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L3. 0 _ Customer owned or furnished material, and MTL procured
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supplies.or services accepted shall be released for 1
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- additional processing or storage, as applicable.
'4. 0 ! Customer owned or furnished material, and MTL procured g
supplies or-services, which are not in accordance with L
customer'or MTL order requirements shall be rejected and
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l processed in accordance with instructions contained in i
. Quality Assurance Procedure, MTL PROCEDURE 15, titled "Non-conforming Materials".
5.0 Records shall be initiated, maintained, and filed in
~accordance with instructions contained herein, or
-Quality Assurance Procedures referenced.
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MATERIAL TESTING LABORATORIES, INC.
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. PURCHASE ORDER NUMBER:
LAB NUMBER:-
--COMPANY NAME:
DATE:
WELDERS NAME:
SSN:
PIPE / PLATE:
POSITION:
STANDARD:
' WELDER QUALIFICATION:
PROCEDURE QUALIFICATION:
j POINT OF CONTACT:-
PHONE. NUMBER:
WORK TO BE ACCOMPLISHED PERFORMED BY DATE COMPLETED.
-1.
Work Order filled out L-2.
Radiographic testing of pipe / plate
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Film &-work order returned to office-
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Qualification papers q
prepared (if necessary) 5.
Company / welder notified of results REMARKS:.
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MTL' DAMAGED OR DEFECTIVE MATERIAL REPORT FROM:
TO:
WORK ORDER NO.
ORDER NO.
ITEM DESCRIPTION
. DEFICIENCIES INSPECTION STATUS QTY.
QTY.
QTY.
INSP.
ACC.
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l-L PREPARED BY:
DATE l
TITLE:
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i CUSTOMER. VERIFICATION DEFICIENCIES IDENTIFIED BY THIS REPORT HAVE BEEN VERIFIED AND i
FOUND TO BE AS STATED.
VERIFIED BY DATE l
TITLE:
COMPANY / AGENCY
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- MTL PROCEDURE 11 - STORAGE, HANDLING, AND DELIVERY.
- 1. 0 ' Identification _and control of. controlled materials received (and other material'if directed by P. O.') and completed work shall be controlled utilizing color in'accordance with applicable quality assurance procedures.
n 1.1 Upon receipt of customer owned. material or.MTL purchased material, the POR shall prepare and apply q
a " Receiving Inspection Hold Tag"'.to the item, U
y shipment container, or pallet-received, or he'sh'all'
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prepare an MTL Work Order and forward the yellow J
copy with the material digectly to the assigned d
p inspector.
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- 1. 2.
Materials shall be moved to designated holding area (s) l pending receipt inspection in~accordance with Quality Assurance Procedure, MTL PROCEDURE 10, titled " Receipt-
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. Inspection".
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1.3 The " Receiving Inspection Hold Tag" (when used) shall
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l be removed and replaced, as applicable, with " Process 1
Inspection Tag" (Yellow), or with yellow copy of work l-order, for customer owned material accepted for inspection.
A red "Non-conforming Material Tag" (if l
required by customer order) shall be placed on non-conforming customer materials or purchased l-material.
An " Accepted Material Tag" (Green) l shall be attached to customer materials meeting 1
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O inspection criteria (when tagging is required by
. customer purchase order or contract.
l 2.0 Customer owned materials received shall be stocked in a controlled-manner utilizing racks, bins, pallets, boxes, or other suitable storage container segregated by MTL job number to prevent mixing of materials, to preclude withdrawal error and to control the processing of materials.
l 2.1 Materials shall be adequately protected during storage to prevent dissimilar metal contact and material deterioration.
3.0 Materials which have been inspected and determined to be in accordance with customer order requirements shall be tagged u
with an Accepted Material Tag and released for packaging, i
packing and marking operations and shipment to customer.
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3.1 Materials which are not in accordance with customer l
order requirements shall be tagged with a
" Nonconforming Material Tag" (RED) and processed in accordance with Quality Assurance Procedures, MTL PROCEDURE 15, titled " Nonconforming Material".
4.0 Material shall be packaged, packed and marked in accordance with customer order requirements and documentation referenced therein.
Packaging, packing and marking operations shall be inspected in accordance with instructions contained in MTL Process Inspection Record defined in Quality Assurance Procedure, MTL PROCEDURE 14, titled " Inspection and Testing".
4.1 Should the customer order not define packaging, packing
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s and: marking ; requirements, material. shall 1x3 packaged and'packedito protect-against corrosion, deterioration, physical ~and mechanical damage during shipment or-g normal storage conditions.
Unit.and exterior-
- l-1; Leontainers,.shall.as a minimum, be marked-'and-labeled-l by any means which'provides' legibility as.followss-l 1.
Nomenclature (item description, part'no.,'etc.')
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2.
Quantity and unit of issue
- 3..
Customer order number i
4.-
Additional markings considered essential to assure proper shipment to customer y
5.0 Records shall be initiated,-distributed, and filed in accordance with instructions co'ntained herein, or qualit'y assurance procedures referenced.~
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MTL PROCEDURE 12 - DOCUMENTATION, DRAWINGS, AND. CHANGE CONTROL.
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The POR'shall identify, maintain, and control documentation,
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drawings,;and related instructions, including the latest
. changes thereto, as applicable, referenced by the customer order.
Customer must furnish documents not held by MTL.
t 1.1 Documentation requiring control shall include, as
. applicable, but not be limited to:
1.
MTL Quality Assurance Manual, Procedures and Documentation 2.
Customer Documentation 3.
Agency.(i.e. ASTM, ASME, ANSI, etc.), military, or federal specifications 4.
Additional documentation, records, or-l f
g correspondence generated by MTL or customer s.;r 2.0 MTL Quality Assurance Manual, Procedures, and Documentation shall be issued in total or partial sections, as'necessary, to MTL personnel performing quality assurance functions, tasks, inspections, or tests, and to the customer, or their representative on a controlled basis only.
The POR shall maintain a Manual / Procedure Distribution Record to identify holders of controlled copies of MTL Quality Assurance Manual and Procedures.
The distribution record shall be maintained in the front of the master copy of the QUALITY RSSURANCE MANUAL which shall be kept in the custody of the POR.
1
Q 2.1 Manuals, Procedures and Documentation issued may not be 4>
transferred to other personnel nor reproduced without approval of the' President of MTL.
p 2.2 The Manual, Procedures-and Documentation may be revised in total or in part.
Revisions shall be identified on each page of the manual or procedures.
1.
Partial revisions or changes shall be identified in the margin of each page revised by a number (1), (2), etc. with the change underlined.
2.3 Revisions or changes shall be forwarded with a cover
)
letter containing disposition instructions to holders of controlled manuals.
3.0 Specifications, drawings and related items shall be handled in the following manner:
3.1 Customer specifications and drawings which apply only.
j to a specific job shall be retained in the order file.
3.2 General Specifications and standards shall be filed in j
i the chemistry office, NDT Office, or other locations as' j
designated by the POR.
The location of these documents
')
shall be recorded on a master Documentation Locator List maintained by the POR.
This Documentation Locator List shall be divided into headings of documentation category (i.e. MIL-STD, FED-STD, MIL-Specifications, etc.).
Within these categories documentation shall be listed in alphabetical and/or numerical order.
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l 3.3 Agency specifications, inspection, and test methods l ' ")
contained in books or bound volumes shall be available i
and maintained in the office of the President of MTL.
1 No documentation file record will be initiated for documentation contained in books or volumes.
1 4.0 Should copies of applicable specifications, drawings and l
related instructions not be on file at MTL, the POR shall request or obtain copies from the customer or issuing activity.
4.1 Upon receipt of new documentation, the pOR shall revise the Documentation Locator List and immediately I
forward to all points of use.
(NOTE:
Often superceded documents must be kept on file for use on contracts that were initiated in prior years.
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Special caution should be exercised in this regard when disposing of superceded documents.)
5.0 MTL shall initiate and maintain records in accordance with instructions contained herein.
3
O LMTL PROCEDURE 13 - SAMPLING INSPECTION 1.0 Supplies or services shall be inspected, accepted and rejected in accordance with sampling plans, methods, or l
criteria referenced by customer order.
2.0 The POR shall be responsible for assuring that customer l
L specified sampling plans, methods, or-criteria are
. properly identified on e.pplicable MTL documentation, inspection, or test records.
3.0 Should the customer order not specify a sampling plan, method, or establish criteria, sampling inspection shall be in accordance with instructions contained in applicable 1
material specifications, or MIL-STD 105, as revised or amended.
4.0 The sample size to be inspected shall be determined
'h according to the classification of defects specified by the applicable material specifications, or the sampling plan utilized by MTL.
4.1 When the sampling inspection plans of MIL-STD 105, o.s amended or revised, are utilized, sampling inspections shall be performed in accordance with the following instructions unless otherwise specified:
1.
Critical - Level II, AQL - 1.0 2.
Major - Level II, AQL - 2.5 3.
Minor - Level II, AQL - 4.0
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4.2 If AQL, critical, major, or minor classification
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are not_specified by customer contract or purchase f
order, inspection and test of supplies or services g
u shall be Level II, with AQL of 4.0
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'Should the sample size be equal to or greater than lot size, personnel shall perform 100%
inspection.
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5.0 Records shall be initiated, distributed, and filed in i
accordance with applicable quality assurance procedures.
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o-MTL PROCEDURE 14 - INSPECTICN AND TESTING v>
1.0 MTL shall perform, or have performed, all required i
inspections and tests in accordance with procedures I
or test methods referenced by customer order and U
applicable documentation incorporated therein.
The 1
i POR shall assure:
1.1.That copies of all applicable specifications, codes, drawings and related instructions, applicable to i
materials or services provided, are available prior to inspection by MTL personnel.
1.2 That necessary test controls to assure all required inspections or tests are accomplished in accordance with written procedures which incorporate the requirements and acceptance criteria established by j
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customer order and applicable documentation.
1.3 That inspection and test results are properly j
l documented and evaluated by MTL personnel to assure that all requirements identified by customer i
i order and applicable documentation have been completed.
1!
i 1.4 That mandatory inspection hold point or check points i
which require witnessing or inspection by the customer, 1
or their representative, are identified by MTL i
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documentation.
Inspection or testing shall not proceed without proper notification and compliance with l
specified intervals of time or consent of the customer.
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g such consent shall be documented prior to continuation I
of work beyond hold points.
2.0 prior to scheduling of work, the pOR shall initiate an applicable MTL Inspection Record to identify inspection and j
L test characteristics, acceptance criteria, customer
. inspection or. hold points, and inspection status.
2.1 The inspection and test characteristics shall be identified to the applicable customer order and inspection document by an assigned number, letter, or paragraph number.
l 2.2 when each required inspection or test is completed, the 1
POR shall indicate their inspection, acceptance or rejection in the appropriaItc section of the MTL Inspection Record.
2.3 The MTL Inspection Record shall indicate the inspection status of materials or services provided which have-been inspected, tested, accepted or rejected.
2.4 The MTL Inspection Record shall be completed, maintained, and filed in the customer order file developed pending, as applicable, review, inspection, and acceptance by the customer, or their representative.
3.0 Materials which are in accordance with customer order requirements and documentation referenced therein shall be tagged (if required by customer purchase Order) with an " Accepted Material Tag" (Green) and released for shipment to the customer.
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1, 3.1 Materials which are not in accordance with customer i/
order requirements shall be tagged (if required by customer P. O.) with a " Nonconforming Material Tag" (Red) and processed in accordance with Quality Assurance Procedure, MTL PROCEDURE 15, titled
" Nonconforming Materials".
4.0 Materials which have been inspected, accepted, or rejected shall be released for packaging, packing and marking operations and shipment to the customer.
4.1 Packaging, packing and marking operations shall be accomplished in accordance with customer order requirements and documentation referenced therein.
4.2 Should the customer order 'not contain packaging, packing and marking requirements, operations shall be accomplished in accordance with Quality Assurance Procedure, MTL PROCEDURE 11, titled " Handling, Storage, and Delivery".
5.0 Records shall be initiated, distributed, and maintained
- ,s in accordance with instructions contained herein or quality assurance procedures referenced.
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MTL RECEIVING INSPECTION HOLD CUSTOMER ORDER NO.
MTL P. O. No.
I Work Order No.
Date Received L
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MTL RECEIVING INSPECTION HOLD 1
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Customer Order No.
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l-MTL P. O. No.
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Work Order No.
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N MTL NONCONFORMING MATERIAL TAG 1
Customer Order No.
MTL P. O. Ko.
Work Order No.
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MTL ACCEPTED MATERIAL TAG
)
Customer Order No.
MTL P. O. No.
Work Order No.
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MTL PROCEDURE 15'- NON-CONFORMING MATERIALS
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1.0 Nonconforming materials or services received,. work in l
process, or completely inspected materials or services L
shall be tagged with a nonconforming material tag prepared q
by the POR and isolated in an adequately identified holding i
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area or container to prevent use, shipment, or intermingling L
with conforming supplies.
2.0 The POR shall initiate a " Corrective Action Request" to u
identify nonconforming materials and to initiate corrective i
action in.accordance with Quality Assurance Procedure, MTL 1
PROCEDURE 16, titled " Corrective Action".
2.1 Nonconforming materials shall not be removed from
- lq reject area or container without approval by the POR.
j f) 3.0 'Should the customer, or customer's representative, determine that materials or services performed and. delivered by MTL are not in accordance with customer order or documentation-
,1 referenced therein, the POR shall initiate an investigation l
upon receipt or notification of a customer complaint.
1 3.1 The investigation to be conducted shall include, as i
applicable, but not be limited to review of MTL or vendor records available at the facility to determine:
1.
The type and amount of inspection and testing
.j performed related to specified deficiencies 2.
The nature and number of deficiencies found during
)
inspection and testing
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.If specified deficiencies existed at time of..
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fy inspection and shipment 4.
If specified deficiencies exist in supplies or u
l services of the.same type of' inspections currently.
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,4 in process.
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If the deficiency is'related to materials or,, J. ,sy< 7 . services procured from a: vendor, thefPORE MS m. 4m L . q m.7y; g shall'initiateacorrective.actionrequestlinM[ q o l' .accordance with Quality Assurance Procedure,. (lj u MTL PROCEDURE 16, titled'" Corrective Action"U V' .q.,, iW 6. If an exhibits required . d, 3.2 The POR shall initiate a letter titled " Customer .?>- ComplaintLInvestigation Findings" which shall' include,: -- i,d .as applicable, but not be limited to: 2a! 1. MTL responsibility (valid or invalid complaint)' h R
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Summary of findings i 3. Corrective Actions' initiated or completed. 4. Additional information considered essential byjPOR?
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'4.0. Should the POR not-complete their investigation by specified?- O d . l
- i customer suspense due date, an interim reply shall be forwarded indicating progress to date, tentative findings,;
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conclusions, actions taken and expected completion date. 'l i S. L, L m) 4 ? 'k'- 1 Qb ); b[} $ r L aadew1CY'? i
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- 4.2. One' copy of each interim lor final reply shall be.
1" ' G ' maintained and. filed in the customer order file. "3 ^ 1 . 5.0; Records shall be' initiated, distributed,_and filed in ,l h 'i accordanc'e with instructions contained herein or= quality j p t ,F, 11 assurance. procedures referenced.- N y I i -b { r' q eI w e )r 3 ,1 s t i q d u X: - ( .r-i- .[. .s 4 .r .(. /i 4 x l . it - i L i y 'I /f ( .i M, dIi a I fM E.l x .n..
4 a [ LNTL' PROCEDURE 16 - CORRECTIVE ACTION j -1.0 Whenever it is determined that materials or services I received, work in process, or inspected materials or I i services are not in accordance with-MTL or customer 1 1 order requirements, the POR shall initiate a Corrective W l Action Request in accordance with instructions contained l l herein. 1 1.1 The Corrective Action Request shall include, as applicable, but not be limited to: 1. MTL data and references 2. Customer data and references 3. Deficiencies 4. Corrective Action Reg'uest 5. Evaluation data h-6. Additional information considered essential 2.0 The POR shall request that the customer," vendor, or MTL personnel, as necessary, initiate corrective action in meeting MTL or customer order requirements and documentation referenced therein. If deficiencies can not be corrected immediately, the POR shall take interim preventive measures, as necessary, to assure that materials are properly-inspected, such as the use of more stringent and thorough inspections. This action will provide for both the correction of potential, as well as actual causes that are detected. th -
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3.0 Upon receipt of corrective action replies, the POR shall I review the replies received and determine if corrective action is considered adequate. 3.1 should corrective action initiated or taken not be considered edequate, the POR shall advise the vendor (s) or MTL personnel of the evaluation, and request that additional actions be initiated. -Additional corrective action requests shall be processed in the same manner as the original. 4,0 Unless otherwise specified, one original and two copies of each Corrective Action Request initiated shall be forwarded to tb3 customer or vendor providing nonconforming materials or services. One copy of each ' Corrective Action Request issued for nonconforming supplies or services processed or ') performed by MTL personnel shall be forwarded to the responsible supervisor. 4.1 One copy of each Corrective Action Request initiated shall be retained in the customer order file developed pending completion of requested corrective action. Upon completion of corrective actions, and evaluation ~ of actions taken, the copy retained in the file shall be destroyed and replaced with returned corrective "U Action Request. 5.0. Records shall be initiated, distributed, and maintained in~ accordance with instructions contained herein.
A O l MTL CORRECTIVE ACTION REQUEST ~b i l FROM: TO: l A q] L WORK ORDER NO. ORDER NO. MTL P.O. NO. _ 'h MATERIAL /SERWICE DESCRIPTION REFERENCES j .i y b l l CAR NO. NONCONFORMING MATERIAL TAG NO. DATE ISSUED APP N/A CHARACTERISTICS APPLICABLE TO THIS REQUEST Please be advised that the ( ) material ( ) services procured on MTLV P.O. No. have been rejected and payment of your invoice l number is being withheld pending resolution o,f-deficiencies below. ( ) Vendor ( ) Customer notified of deficiencies I identified below. Notification to ']) Date Notified by Disposition instructions: It is requested that an immediate investiga-tion be initiated to determine the cause of deficiencies identified below. In addition, it is requested that a copy of your findings and corrective actions initiated or taken to eliminate deficiencies of this nature on future shipments to MTL be forwarded no later than In the event actions can not be completed within specified suspense date, please specify date same will be completed. DEFICIENCIES ISSUED BY DATE
T J t i . I DEFICIENCIES (CONTINUED)- l .-).. t .d '[ r .) ) l' ..i J l.. i \\ F-l .) i s b i S h ), -ij 4 1-g l ~ 1 ) l cf l Jil 1
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o-MTL PROCEDURE 17 -' RECORDS h 1.0 MTL personnel shall initiate, distribute, and file records in-accordance with instructions contained in each quality l [ assurance procedure. 2.0 The records initiated shall be utilized to provide objective quality evidence that all materials inspected, inspections, tests, operations, or work performed are in accordance with customer order requirements. 2.1 The records shall indicate the nat'ure and number of observations made, deficiencies found, the quality of materials or services approved or rejected, and the l nature of corrective action initiated. 2.2 Criteria for approval or r' ejection of materials or services processed shall be in accordance with customer 'h order and documentation referenced therein. 3.0 The POR shall review MTL and vendor records upon receipt to assure they are legible, properly completed, identifiable by: customer or MTL order requirements, and that certifications and records processed contain all required inspections,- tests, test value and statements necessary to certify materials or services prior to inspection or shipment to the customer. 3.1 Personnel shall indicate their review, acceptance, or rejection of each document by stamping, signing, dating, and marking (x) accepted or rejected. 3
o s: ) o~ 3.2 MTL-or vendor records and certifications for materials \\)- or services which are not in accordance with customer order requirements shall be rejected. .g ;; 1. The materials or services identified.by rejected-t documentation shall be processed in accordance with Quality Assurance Procedure, MTL PROCEDURE 15, titled "Non-conforming Materials". 1 4.0 Customer order files and related docume.ntation generated as-1 q a-result of this inspection system shall be retained on file. in accordance with customer order requirements, when specified. 4.1 - Should the customer order not specify record retention' l period, files developed shall'be retained for the warranty period specified for materials or services I procurred by the customer. l 4.2 Should the customer order not specify a warranty period, the file developed shall be retained for i a period of two years. 5.0 Records shall be initiated, distributed, and filed in l accordance with applicable Quality Assurance Procedures i or instructions contained herein. l j l J I -l l
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