|
STEP |
WHO |
WHEN |
INFO
TO USE |
WHAT
TO DO |
RESULTS |
| 1 |
Any supervisor or other team
member responsible for verifying conformance of parts |
As containers of parts are found
to be questionable or otherwise needing MRB* review |
Production Traveler and contents of QC inspection folder;
blue print (s); tags on parts containers; own judgment |
Tag any questionable parts with
a green Disposition Tag clearly identifying who, when and why for the hold
then place yellow Hold Tag over green Disposition Tag; have parts
immediately moved to MRB** area; notify QA Manager and QC Supervisor via
email.
|
Questionable parts identified,
tagged, and QC notified. Parts in MRB** area |
| 2 |
QC team
member |
Upon
notification from team member that nonconforming parts have been identified
and tagged |
Production Floor Traveler and contents of QC
inspection folder; Part inspection sheet; Discrepancy report, emails
regarding discrepant parts, blue print (s); tags on parts container; own
judgment |
Ensure
that the appropriate documents regarding discrepant parts have been issued;
send parts to MRB** area if an immediate resolution is not possible. |
Appropriate documentation started on nonconforming product |
| 3 |
Material Review Board (MRB)*: QC Supervisor with any other team member |
Once a
week (daily if needed) |
Contents of QC
Inspection folder; Production Traveler, tags on parts; blue print (s); discussions with other
managers or customer |
MATERIAL REVIEW BOARD: Review parts in MRB** area or where possible
nonconforming parts are found; determine disposition of the part,
bringing in other team members as deemed appropriate (especially include
VP Quality and Engineering and QA Manager for difficult problems); ensure
that parts are dispositioned per Board's plan; if nonconforming parts are
thought to be acceptable as is,
then
remove yellow Hold Tag and
green Disposition Tag and process parts according to Traveler; if rework is
needed, remove only the yellow Hold Tag and write disposition on green
Disposition Tag; complete appropriate documents regarding discrepant
parts and hold job file open until any re-workable parts are reworked and
re-inspected; record results of inspection on nonconforming product
documentation when job is complete; place copy with MPS or Production
Traveler; forward
to QA Clerk or Machining Department Clerk.; if scrap
rate is too high review parts with hammerman or QC team member; or
machine operator for scrap requirements per TOP-SCRAP;
as deemed necessary, request Corrective
Action Report (CAR) TOP-CARRR
. |
All
questionable parts reviewed and disposition determined; nonconforming
product documentation filled out and forwarded to QA Clerk. CAR issued, if necessary. |
|
4 |
QC Supervisor |
Customer acceptance/rejection is
required of non conforming parts |
Production Floor Traveler;
Disposition Tag |
Place Job Order on hold in M2M; notify MRB Members
by email; remove
Production Floor Traveler from circulation (to prevent parts from being
shipped) and place in QC Office file folder marked NOCON; have Shipping Leadman
or Clerk ship sample part(s) to customer
for acceptance/rejection. |
Job Order on hold; Production
Floor Traveler removed form circulation; Customer Service Rep notified; sample part(s) sent
for customer acceptance/rejection |
| 5 |
QC Supervisor |
Customer notification that sample parts are accepted or rejected |
Reply from Customer that
sample parts
are accepted or rejected |
If
parts are accepted notify Customer Service Team member; remove Disposition tags; put
Production Floor Traveler back into circulation and take parts off hold in
M2M. If parts are rejected notify Sales Representative; setup a new job order in M2M. |
Parts
accepted for shipping
Parts rejected
and new job order is set up in M2M |
| 6
|
QC Supervisor |
Upon MRB* determining disposition
of questionable parts |
MRB*
decision; Final Inspection Report; Nonconforming Product Report; blue print
(s)
|
Record results of MRB* decisions
distribute via e-mail spelling out when team members need to take action
(members are to respond by email to all); document all non-conformances and dispositions on Final
Inspection Report (specifically verifying destruction of any faulty parts,
instruct QA Clerk to close out Final Inspection Report when re-inspection is
fully complete; if customer approves out-of-spec parts, notify Customer Service Rep.
|
All
questionable parts double-checked, HOLD tagged and routed appropriately;
customer approval received, documented in PO file; Final Inspection Report
completed |
*MRB Members: Quality Assurance
Manager, VP of Quality & Engineering, Quality Control Forging Supervisor,
Quality Control Machining Supervisor, Post
Forge Supervisor, Production Control Manager and Machining Manager.
**MRB Area must be chained or roped off and clearly marked. This could
include temporary areas defined by agreement of Quality Control
Forging
Supervisor, Quality Control Machining Supervisor and Post Forge
Supervisor.
Primary, Critical and Flight Safety Parts must be stored in a secured MRB
location designated by the Quality Assurance Manager until dispositioned by the customer.
