1 control of non-conforming product & materials

QC

1. Type 2 Nonconformance
notification
Floor Plan – Hold Area, Quarantine Area, Scrap Area
Outdoor Storage Plan
SOP-0000 Control of Non-conforming Product & Materials
Start
Unidentified, unlabelled or
non-conforming materials
or products found during
Internal/External, Process
or Customer Audits, health
& safety audits, Materials
Management or by
housekeeping are
segregated and identified
as non-conforming
WI-______Process Audit
WI-____ Health & Safety Audit
WI-5021 Safe Handling of
Chemicals
WI-7002 Handling and
Storage of Raw Materials
Identification & Segregation
As applicable,Supplier Quality Specialist or Quality Assurance Supervisor
ensures suspect or known non-conforming materials are clearly identified &
segregated or moved to designated HOLD/Quarantine area
Customer
returns non-
conforming
product or
notifies The
Company of
Warranty issues
resulting in
known or
suspect Non-
conformances
Customer Communication
Customer
Corrective
Action Request
Quality
Assurance
Department
upon notification
fromSupplier,
initiates action to
trace, identify &
segregate
suspect/non-
conforming
materials
WI-____ Processing of Defects
Notification by
Supplier of defective
Shipped Parts
External Returns
Engineering Design
change results in
obsolete materials
which must be
identified and
segregated
SOP-0011 Change Control – Product, Process, Sourcing
In-Process Handling / Production
Engineering
Process/ Customer / Health &
Safety Audits, Materials
Management & Housekeeping
Respective Test/
Audit results in
identification of non-
conforming product
Per Quality Inspection and Test Plan (QITP)
Annual Validation
Testing
Receiver/Quality Assurance
identify & segregate suspect
or non-conforming materials
during inspection of incoming
material or supplier
qualification
WI-7001 Receiving Inspection
of Raw Materials
WI-7000 Bulk Tanker
Offloading
WI-5011 Testing Version Density
WI-5012 Testing Version Pot
Life
WI-5013 Testing Version
Viscosity
WI-5014 Testing Isocyanates
WI-5015 Testing Version
Resin
WI-5018 Receiving Inspection of Fibreglass
Receiving Inspection - Supplier
Qualification
5.2 Customer Focus
7.2.3 Customer Communication
7.4.3 Verification of Purchased Product
7.5.5 Preservation of Product
7.5.3 Identification & Traceability
8.3 Control of Non-conforming Product
8.3.1 Control of Non-conforming Product - Supplemental
8.3.3 Customer Information
4.2 Quality Requirements 4.6 Periodic Re-qualification 4.16 Customer Feedback
Production and/or
Quality Assurance Personnel identify &
segregate known or suspected non-
conformances
WI-3043 Isocyanate and Resing Handling
WI-3039 Nitrogen Blanketing
WI-3044 Resin Agitation Totes
WI-5003 Cup Test
WI-5006 Ratio Check
WI-5016 Gel Time Test
WI-5002 Process Inspection
WI-3001 Cutting Modules to Length and
Weighing
WI-3009 Drilling Modules – Standard Holes
WI-5005 Physical and Dimensional
Inspection
WI-5004 Marking, Drill Hole, Slot Inspection
WI-5007 Module Disposition
WI-7003 Transfer of Modules
WI-7004 Order Preparation
WI-3010 Packaging and Shipping Poles
WI-3045 Cutting Poles to Length & Top
Caps
WI-3042 Custom Drilling
WI-3014 Preparing Module & Pole ID Tag
WI-5027 Shipment Inspection
Incidents of known or suspected product or
process non-conformances
may arise or be identified during the
implementation of any of the activities identified
below (blue boxes).
The respective controls, responsibilities, and
authority are detailed in the applicable
Work Instructions (red text)identified
under each of the individual scenarios
4.2.4 Control of Records
As applicable:
Inspection Labels
On Hold – FAIL Tag (F-5004)
NCR – Quarantine Tag (F-5011)
Customer Notification/Warranty
Issue
Customer-specific Requirements
(Type 1 and Type 2 Non-
nonconformance)
Determine disposition Authority
Quality Lab Technician
per applicable Work Instruction assesses suspected or identified non-
conforming materials/products to determine the Disposition authority
Type 1Authority: The Company
Type 2Authority: Customer
Go to
A
Laboratory/Finished
Product Testing
Quality Assurance
Personnel identify
& segregate known
or suspected non-
conformances
WI-3040 Preparing
Test Specimens
from Modules
WI-5000 Flex Strength & Modules Test
WI-5001 Interlaminar Shear Strength Testing of Tubular Composite Samples
WI-5008 Density,
Void Content and
Glass Content Test
See CSR…...Type 1 and Type 2
Processing Non-conformances
Quality Lab Technician
per applicable Work Instruction
1) Implements Customer-defined dispositioning instructions or
2) Determines & assigns disposition of one of the following:
- Return to Source - Scrap - 3
rd
Party Sort
- Rework/reuse - Send to Lab for testing
- Hold - Customer/Internal Waiver
3) communicates disposition status as applicable to ensure that customers are promptly
informed of issues which might impact them (Supply Chain Coordinator notifies
customer of any actual or potential supplier issues, or potential supply or capacity issues
and Q.A. Manager notifies customer of any actual or potential non-conforming product
which may have been shipped)
4) maintains records of the nature of all nonconformities,
(including “suspected nonconformities” which are
subsequently approved, and any actions taken,
including concessions/waivers obtained)
Customer to
Disposition?
Customer
communicates
disposition status
and required
actions, as
applicable
Yes
Nonconformance Monitoring Records
Customer Waiver
Disposition Labels, as appropriate:
F-5015 Engineering Test Label
F-5021 Lab Sample Label
F-5004 On HOLD/FAIL Tag
F-5010 PASS Tag
F-5011 Do Not use/Hold/NCR
F-5031 Interim PASS (Orange)
Customer
communication
No
Non- conformance Type
ISO 9001
Customer-
specifics
This printed document is an UNCONTROLLED COPY - Check B.O.S. to verify validity prior to use Date printed: Saturday, July 12, 2008
Patricia Ravanello - Management Systems SOP-0012 Control of N on-Conforming Product and Materials, Revision: 0 Page: 1 of 3

2. As applicable:
Nonconformance Report
Customer Waiver
Disposition Labels, as appropriate:
F-5015 Engineering Test Label
F-5021 Lab Sample Label
F-5004 On HOLD/FAIL Tag
F-5010 PASS Tag
4.2.4 Control of Records
8.3.4 Customer Waiver
4.2.4 Control of Records 8.5.2 Corrective Action
7.1.4 Change Control 8.3.2 Control of Reworked Product 8.5.2 Rejected Product Test/Analysis
Repair/Rework
Respective Responsible Party takes action to:
eliminate the detected non-conformity
authorize its use, release or acceptance, under concession by a relevant
authority, and where applicable by the customer, or
preclude its original intended use or application
and initiates corrective action per SOP-0000 Corrective and Preventive
Action and Continual Improvement and/or the applicable
Work Instruction as identified below, ensuring that records
of the results of action taken are maintained
Customer/Supplier/Internal
Waiver
Quality Assuranceensures
that:
Customer Interim
Authorization is obtained
prior to further processing
whenever the product or
process is different from that
which is currently approved and
that records are maintained of
the expiration date and quantity
authorized per
SOP-0011 Change Control
WI-5____ Processing
Engineering and Document
Change Requests
Responsible party
(per applicable W.I.)
identifies instructions for re-work
identifies re-inspection
requirements to ensure
effectiveness of corrective
action
ensures that the above is
accessible and utilized by the
appropriate personnel.
WI-_____ Repair/Rework
Management
Go
To B
Design Change
SOP-0011
Change
Control –
Product,
Process,
Source
WI-7___
Management
of Obsolete
Material
Scrap/Disposal
WI-_____
Processing of
Defects
WI-______
Quarantine
Area
Management
WI-5021 Safe
Handling of
Chemicals
Purge
WI-_____ Processing of Defects
Purging of
Raw
Materials
In process
Finished Product
Return to
Source
WI-____
Processing
of Defects
WI-______
Quarantine
Area
Managemen
t
A
SOP-0000 Control of Non-conforming Product & Materials
- See respective output of
processes (Work
Instructions) identified
below
This printed document is an UNCONTROLLED COPY - Check B.O.S. to verify validity prior to use Date printed: Saturday, July 12, 2008
Patricia Ravanello - Management Systems SOP-0012 Control of N on-Conforming Product and Materials, Revision: 0 Page: 2 of 3

3. Metrics DASHBOARD
Non-conformance Monitoring
Records
Rework Records
Scrap Records
Repair Records
Spill Records
Supplier PPM
SOP-0000 Control of Non-conforming Product & Materials
B
End
Department Managers
monitor and assess the nature and frequency of non-
conformances per
SOP-0000 Monitoring, Measurement and Analysis
and report analysis and conclusions to
Senior Management per
SOP-0000 Business Planning and Management Review
1) to verify the suitability and effectiveness of the
Business Operating System,
2) to monitor progress toward objectives
3) to assess the need for additional resources, and
4) to identify or evaluate opportunities for continual
improvement
- Management Review Meeting Minutes
(Actions/Responsibilities/Timing)
- Resource Requirements
- Opportunities or recommendations for
continual improvement
This printed document is an UNCONTROLLED COPY - Check B.O.S. to verify validity prior to use Date printed: Saturday, July 12, 2008
Patricia Ravanello - Management Systems SOP-0012 Control of N on-Conforming Product and Materials, Revision: 0 Page: 3 of 3