|
STEP |
WHO |
WHEN |
INFO TO USE |
WHAT TO DO |
RESULTS |
| STEPS 1 - 8 APPLY TO NONCONFORMING STEEL OR
OTHER METALS TO BE FORGED OR
MACHINED. |
| 1 |
Steelyard Specialist or Steelyard
Supervisor |
Upon identifying a potential problem
("nonconformance") with steel or other
metals to be forged or machined prior to its being
cut |
Personal observation, supplier paperwork or test
results |
Notify Production Supervisor or Materials Manager
as soon as possible (ideally while material is still
on truck); initiate RMNR (Raw Material Non-conformance
Report); if material must be unloaded,
place it in the "Quality-Hold" bin; tag any
material that is in process with a "HOLD"
tag and keep the material isolated; DO NOT USE
ANY QUESTIONABLE MATERIAL UNTIL ISSUES ARE RESOLVED
BY THIS PROCEDURE. |
Questionable material on truck or isolated;
management notified; Raw
Material Non-conformance Report
initiated |
| 2 |
Hammerman, crew member, inspector or any team
member |
Upon identifying a potential problem
("nonconformance") with raw material during
cutting, forging or inspection |
Personal observation |
Notify immediate supervisor or other available
supervisor. |
Supervisor notified of potential problem
("nonconformance") with raw
material |
| 3 |
Supervisor |
Upon notification or personal observation of
potential problem ("nonconformance") with
raw material |
Notification from team member or personal
observation |
Initiate RMNR and notify Production Supervisor or
Materials Buyer. |
RMNR initiated and Production Supervisor or
Materials Manager notified of potential problem
("nonconformance") with raw
material |
| 4 |
Production Supervisor and Materials
Manager |
Upon receiving notification of questionable raw
material |
Verbal notification and/or
RMNR |
Get together and look at material; be sure it is
properly isolated from any material that is approved
for use; determine material disposition together (may
have to forge a few pieces of the material in order
to determine its suitability under the close
supervision of the Production Supervisor and, if
necessary QA Manager instruct ions as to proper
disposition of bad parts due to nonconforming
material); use any third parties as needed, including
other team members, outside testing labs or the
supplier. If an agreement cannot be reached, the
President decides. |
Decision regarding raw material
disposition--possible choices: material acceptable,
material may be used for limited applications or
after surface processing (possibly hold pending
supplier concession), or material is unacceptable and
must be returned |
| 5 |
Production Supervisor and Materials
Manager |
Upon determining material is OK to
use |
RMNR; decision from step 4 |
Notify Steelyard to put material back in normal
system and record decision on
RMNR. |
Material ready for use and decision recorded on
RMNON spread sheet. |
| 6 |
Materials Manager |
Upon material being identified as
nonconforming |
RMNR; decision from step 4 |
Record decision on RMNR; compare this RMNR with
Open & Closed RMNR file; if an adverse trend is
identified, initiate a Corrective Action Report (per
TOP-CARRR). |
Raw Material
Non-conformance Report filed in Open RMNR
file; CAR if adverse trend |
| 7 |
Materials Manager |
While RMNR open (reviewing at least
weekly) |
Open RMNR |
Continue negotiations with supplier regarding
final disposition of nonconforming material,
continuing to use Production Supervisor and other
resources as needed until issue resolved; upon
resolving immediate issue, add info to RMNR regarding
immediate actions and route copy of RMNR to
distribution list (also seeking ideas as to future
actions or procedural changes to prevent similar
situations); add notes regarding limitations of
material to Steel info on
computer. |
RMNR routed; Steel info
up-to-date |
| 8 |
Steelyard Specialist or Steelyard
Supervisor |
Upon material being identified as
nonconforming |
RMNR |
If material
rejected:
If material still on
supplier's truck, send truck back unloaded;
otherwise, hold in Quality-Hold bin (or tagged in
isolated area if already cut) awaiting instructions
to scrap or to return material to supplier when
truck is provided.
If material accepted for limited
application or with processing:
Get any processing done then
handle through normal raw material receiving
procedures (TOP-RECRM),
adding notes to bundle tags and ensuring similar
notes are in Steel info on
computer.
|
Steel returned or placed into
quarantine and later scrapped or
returned; Material back into process
(possibly with limitations noted on tag and in
computer)
|
| STEPS 9 - 14 APPLY TO NONCONFORMING RAW
MATERIALS "OTHER" THAN STEEL OR METALS TO
BE FORGED OR MACHINED |
| 9 |
Manufacturing Manager |
Upon identifying a potential problem
(non-conformance) with bolts, paint, springs, pins or
"other" raw materials that are to be used
as part of the finished product (see TOP-RECOM) |
Accompanying paper work; part drawing; purchase
order; material specifications |
Notify the Materials Manager; initiate the
Raw Material Non-conformance
Report (RMNR); tag any material with a
"HOLD" tag and keep it isolated; DO NOT USE
ANY QUESTIONABLE MATERIAL UNTIL ISSUES ARE RESOLVED
BY THIS PROCEDURE. |
Questionable material tagged and isolated;
Materials Manager notified; RMNR
initiated |
| 10 |
Materials Manager |
Upon being notified of potential problem
(nonconformance) |
Notification and/or RMNR |
Look at material; be sure it is properly isolated
from any material that is approved for use; determine
material disposition; use any third parties as
needed, including other team members, outside testing
labs or the supplier; if an agreement cannot be
reached, the President decides. |
Decision regarding raw material disposition
possible choices: material acceptable, material may
be used for limited applications or material is
unacceptable and must be returned |
| 11 |
Materials Manager |
Upon determining material is okay to
use |
RMNR; decision from step 10 |
Notify the appropriate person to put the material
back in normal system and record decision on
RMNR. |
Material ready for use and decision recorded on
RMNR |
| 12 |
Materials Manager |
Upon material being identified as
non-conforming |
RMNR; decision from step 10 |
Record decision on RMNR; compare this RMNR with
Open & Closed RMNR file; if an adverse trend is
identified, initiate a Corrective Action Report (per
TOP-CARRR). |
Raw Material
Nonconformance Report filed in Open RMNR
file; CAR if adverse trend |
| 13 |
Materials Manager |
While RMNR open (reviewing at least
weekly) |
Open RMNR |
Continue negotiations with supplier regarding
final disposition of nonconforming material,
continuing to use other resources as needed until
issue resolved; upon resolving immediate issue, add
info to RMNR regarding immediate actions and route
copy of RMNR to distribution list (also seeking ideas
as to future actions or procedural changes to prevent
similar situations); see that tags regarding
limitations of material are put on
containers. |
RMNR routed; material tagged with any
limitations |
| 14 |
Steelyard Supervisor |
Upon material being identified as
non-conforming |
RMNR |
If material is rejected, hold in
isolated area while awaiting instructions to scrap
or to return material (paint must be returned) to
supplier (if decision is to scrap, do so per
Materials Manager's
instructions).
If material accepted for limited
application or with processing: get any processing
done, then handle through normal raw material
receiving procedures (TOP-RECOM),
adding notes to container tags and ensuring similar
notes are in the computer, getting Materials
Manager's help if needed. |
Material returned or placed into
quarantine and later scrapped or
returned; Material back into process
(possibly with limitations noted on tag and in
computer)
|
|
STEPS 15 - 17 APPLY TO ALL
MATERIALS |
| 15 |
Materials Manager |
If nonconforming material was
customer-supplied |
RMNR |
Deal with customer as with any other supplier
(see above) and send memo to customer file giving
date, customer ID, name of customer representative
notified, counts, weights and details (attach copy of
all paperwork). |
Nonconforming customer-supplied material issues
documented |
| 16 |
Materials Manager |
When RMNR returns after
routing |
RMNR |
Determine any long-term changes that may be
needed (a CAR may be indicated at this point if not
already done); verify that final disposition of RMNR
includes effective implementation of corrective
action (whether or not CAR issued); file RMNR in
Closed RMNR file. |
RMNR to Closed RMNR file; possibly CAR issued;
effectiveness of corrective action
verified |
| 17 |
Materials Manager |
Annually (typically in
December) |
Open and Closed RMNR files; Steel
info |
Work up a comparative analysis of the various
suppliers to determine relative strengths and
weaknesses; review analysis with QA Manager and issue
any CARs that may be indicated; save report in Closed
RMNR file. |
Supplier performance analysis to Closed RMNR
file; possibly CAR(s) issued |
