Section: QP83-01

Standard:

Control of Non-Conforming Product

Version: 13.0

Date: 25 April 2013

Purpose and Scope

The purpose of this procedure is to establish the method of controlling Non-Conforming products, both supplied to Booth Welsh and also supplied to its customers.

Principle Responsibilities

Operations DirectorWorkshop ManagerDepartment ManagersPurchasing Manager

ActivitiesQP83-01-01 Detection of Non-Conforming ProductsQP83-01-02 Documentation, Identification and SegregationQP83-01-03 Review and DispositionQP83-01-04 Inspection and Test Status

Related ProceduresQP74-01: PurchasingQP75-01: Product Manufacture

FormsQD74-04: Goods Return / Concession NoteQD83-01:   Non Conforming   Product Log QD83-02: Non Conformance Report

Other InformationNo external documents are required.

QP83-01-01 Detection of Non-Conforming Products

Non-conforming products may be detected at various stages of the operation, for example:         upon receipt from a supplier (at Incoming Inspection) during storage (e.g. when checking/rotating stock) during any stage of the manufacturing/test operation prior to despatch to customer (e.g. at Final Inspection) After delivery to customer ( e.g. In use)

Whenever a non-conforming product is detected (or suspected) for whatever reason, the person who detects the non-compliance  or is advised by the customer shall initially notify the Workshop Manager or Department Manager, as appropriate, of the precise nature of non-compliance.

QP83-01-02 Documentation, Identification and Segregation

Once a non-compliance has been confirmed the following process should be used to resolve and track the issue to its conclusion:

1.     The Workshop manager should be advised of and add the non-conformance to his QD83-01: Non-Conforming Product Log and allocate a Non-Conforming Report number (NCR No.) for the issue.

2.     The BW employee that has identified the Non-conformance/or has it reported to shall create a QD83-02: Non Conformance Report . The report should include the NCR No., a brief description of the identified problem and suggested corrective action (where this is already established).  In the instances when the non-conforming product is a “simple” return to supplier a QD83-02: Non Conformance Report is not required and the process should be as below for return to the supplier.

In instances where the non-conformance requires the defective or incorrect equipment to be returned to the supplier, then a QD74-04: Goods Return Note should also be generated and issued to the Purchasing Manager for appropriate follow up with the supplier.

3.     The part completed non-conformance report should then be submitted to the relevant Department Manager and copied to Workshop Manager.

4.     The Department Manager shall then confirm suggested corrective action is appropriate and complete the “Follow Up Action” section of the Non Conformance Report and assign responsibility to an appropriate department representative for follow up action and closure of issue.

5.     In instances where the corrective action requires return of goods to supplier or disposition (see QP83-01-03 below for disposition process) then the Non-Conforming Product should be segregated to prevent unintended use by placing in a designated “Quarantine Area” pending review and disposition.

N.B. These areas are identified by a “Quarantine Area” sign in red lettering in both the production and stores areas.

At this point the product shall also be identified as non-conforming by labelling with a Non-Conforming Product Label indicating:

                           Date                           NCR Ref. Number                           Brief Description of Non Compliance

6.     The appointed department representative will ensure appropriate follow-up actions are completed to resolve the Non-conformance and complete and sign off the “Close Out Action” section of the Non Conformance Report and return the form to the Department Manager.

7.     The Department Manager should then complete and sign off the “Final Review” section of the Non Conformance report and if appropriate have it endorsed by BW employee that has identified the Non-conformance.

8.     The completed Non-conformance should then be returned to the Workshop Manager so that he can file the report and sign off the issue on the Non-Conforming Product Log.

QP83-01-03 Review and Disposition

The Workshop Supervisor or Department Manager shall review the nature of the non-conformance and make a decision on the disposition of the product(s) concerned. This decision shall be based on any relevant manufacturers specification or contractual customer specification as appropriate and will be one of the following:-

         Rework to meet Specified Requirements Accept on Concession (Internal or External) Reject and Return to Supplier Re-grade for alternative application Scrap1.     When a non-compliance cannot be clearly defined or categorised with reference to the

relevant specification, this shall be referred to the QAR for a decision on disposition.2.     When product is to be rejected and returned to a supplier this shall be actioned by

following requirements of QD74-04: Goods Return Note with actions/responsibilities shared between Workshop Manager for logging and Purchasing Manager for dealing with supplier as appropriate.

QP83-01-04 Inspection and Test Status

The inspection status of all work in progress (W.I.P.) shall be maintained and identified throughout the production process via the processes outlined in QP75-01: Product Manufacture Appropriate inspection/test records will be generated to indicate conformance or otherwise to inspections carried out at defined phases of assembly/test. In the event that any Work in Progress (W.I.P) product fails a Production Inspection /Test Stage or is otherwise suspect of damage or deterioration at any stage of the production/test operation, the person who detects the non-compliance shall initially notify the Workshop Supervisor or Contract Engineer of the precise nature of the non-compliance.

Once a non-compliance has been confirmed, details of the non-compliance shall be recorded on the QD83-02: Non Conformance Report and the process outlined in QP83-01-02 above should be followed.

N.B. “On Test” failures or non compliances are dealt with separately and recorded and processed using appropriate Panel Test reports or Sheets.

Revision History

 

 

 

 

 

Version Description of Change Author Date

1.0 Upgrade to ISO9001:2000 guidelines MO 27 Jan 2003

9.0 Edits to QP83-01-02 + minor edit to  QP83-01-04 JF 09 Nov 2010

13.0 Additions to QP83-01-01 + Edits to  QP83-01-02 PR 25 April 2013