8.3 Control of Nonconforming Material
- 1. Quality Procedure ISO9001:2008 – Cuming Corporation Document #: 8.3 Rev.: A Title: Control of Nonconforming Material Page #: 1 of 4 Approval: Approval: 1.0 SCOPE AND PURPOSE This procedure defines requirements for the control of Nonconforming Material. This applies to the identification, control, reporting, and disposition of conforming material. 2.0 RESPONSIBILTIES See Flow chart Page #5. 3.0 DEFINITIONS NONCONFORMING MATERIAL or DISCREPANCY – any material that does not comply with dimensional, visual or hydrostatic specifications, is damaged or was not processed in the manner defined in the Quality Assurance Plan; or, any material/service not meeting requirements set forth in the purchase order. MRB – Material Review Board consisting of Product Development, Engineering, and Manufacturing, and the ensuing agreement of the Quality Assurance Manager. Defect –Out-of-specification condition, resultant from faults in “visual appearance design, process, procedures, that require reporting” using the Discrepant Material Form. Root Cause Analysis – Determining the actual root cause of the defect will be determined by the following departments: Hydrostatic Implosions / Failures: Product Development Mixing issues: Engineering Assistant Workmanship issues: Control Configuration Officer 4.0 INPUTS Discrepant Material Report F4-8.3-F001 Rev. A Manufacturing Traveler F4-7.5-F007 Rev. C Red Scrap Tag 8.5” x 11”
- 2. Quality Procedure ISO9001:2008 – Cuming Corporation Document #: 8.3 Rev.: A Title: Control of Nonconforming Material Page #: 2 of 4 Approval: Approval: 5.0 PROCEDURE 5.1 All suspect nonconforming material shall be identified by the DMR. Defects reported using the Discrepant Material Report (DMR), form number F4-8.3-F001. All discrepant material shall be identified and segregated (if possible) to prevent further processing during the nonconforming material control process. Defective product shall be indentified using Form F4-8.3-F001, or Red Reject Tag. 5.2 The discrepancy is documented clearly, concisely, and in sufficient detail using photos as well to describe exactly what the discrepancy is. References to associated documents and specification shall be noted when applicable. 5.3 When a DMR is initiated, the originator shall use the next DMR number from the DMR Log book. The DMR number shall be noted in the space provided on the DMR form. Electronic copies “are then distributed to individual(s) notated at the “Assigned to:” Hard copies with the product traveler “are given to “Assigned to:” at the morning production meeting. The DMR # will be transferred to the traveler to demonstrate full traceability. 5.4 The discrepancy noted on the DMR by Quality Assurance is reviewed by one or more individuals on MRB to disposition the defective part(s). If the part(s) require rework, adequate instructions are to be applied in the Disposition field. Immediate corrective action is defined by the MRB action. “Possible dispositions include” UAI = Use as is; RTV = Return to Vendor; REWORK; REPAIR; SCRAP; Other (Specify). 5.5 Cycle time of the disposition of the DMR is a maximum of 10 working days. The cycle time of closing the DMR is a maximum of 30 working days. Extreme cases where a CAR is required, cycle time to close the DMR will take longer. The exception to this is when Corrective Action is linked to the discrepancy. 5.6 If needed a root cause analysis will be performed and the findings will be attached to the DMR. The department assigned to this exercise is described in section 3.0 of this procedure. 5.7 Agreement is demonstrated by Engineering or Manufacturing signature and is required for all DMR dispositions. If customer concurrence is necessary, the Project Manager will inform the customer of the nonconformance and forward a copy of the DMR to the customer representative. The customer will return a signed copy of the DMR to Cuming Corp. for inclusion in the customer job file.
- 3. Quality Procedure ISO9001:2008 – Cuming Corporation Document #: 8.3 Rev.: A Title: Control of Nonconforming Material Page #: 3 of 4 Approval: Approval: 5.8 The Quality Assurance Manager shall monitor reports of nonconforming material for trends associated with workmanship, process, materials, or outside services using Statistical Analysis. DMR stats will be included in the management review process. 6.0 OUTPUTS DMR Parato analysis, DMR summary data and DMR database. 7.0 METRICS Quality Assurance Dashboard Revision History Revision Date Description A 4/6/11 Initial Release
- 4. Quality Procedure ISO9001:2008 – Cuming Corporation Document #: 8.3 Rev.: A Title: Control of Nonconforming Material Page #: 4 of 4 Approval: Approval: Discrepant Material Report DMR Number: Reason Code: Location: Incoming Insp.: In-Process: Final: Assigned To: Date: Job Detail: Job # : Part # : Customer Name: Discrepancy: Rework / Repair / Instruction: Authorized Signature:______________________ Person / Dept. Responsible for (Rework Comments): Signature:______________________ Estimated Material Cost: $ Actual Material Cost: $ Estimated Labor Hrs: Actual Labor Cost: $ Total Cost: $ Total Cost: $ Disposition: (Quantity) UAI RTV Rework Repair Scrap Other Root Cause Attached: Yes No CAR Required: Yes No Material Review Board: Approvals Date Engineering Y N Manufacturing Y N Quality Assurance Y N
- 5. DMR Process 8.3 EngineeringQualityAssuranceManufacturing Phase Defective Q.A. generates a DMR (Defective Material Report) DMR document DMR information is logged into database DMR Review Mfg. or Eng. Disposition (Use As Is, Repair, or Scrap) Yes Eng. Scrap Repair Use As Is Send to paint dept. Rework the part(s) Manufacture part(s) Scrap cost collected and applied to DMR Q.A. notifies Mfg. Make new part(s) Inspection Q.A. inspects parts Yes InspectionYes No Disposition (Use As Is, Repair, or Scrap Mfg. Scrap Repair Use As Is Rework Instruction Root Cause Analysis