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…02…PAD/PRC/0002
…02…KJL/820513…02……02…#
NONCONFORMANCE HANDLING
…02…Issue 3…02…GENERAL
T̲A̲B̲L̲E̲ ̲O̲F̲ ̲C̲O̲N̲T̲E̲N̲T̲S̲
1. SCOPE .....................................
4
2. APPLICABLE AND REFERENCE DOCUMENTS ........
5
3. DEFINITIONS ...............................
6
3.1 GENERAL ................................... 6
3.2 NONCONFORMING MATERIAL ....................
6
3.3 MINOR NONCONFORMANCE ......................
6
3.4 MAJOR NONCONFORMANCE ......................
6
3.5 PRELIMINARY REVIEW (PR) ACTION ........... 7
3.6 MATERIAL REVIEW BOARD (MRB) ...............
7
3.7 REWORKED MATERIAL .........................
7
3.8 REPAIRED MATERIAL .........................
7
3.9 SCRAP .....................................
7
3.10 "USE AS IS" MATRIAL ..................... 8
3.11 STANDARD REPAIR METHOD (SRM) .............
8
3.12 CORRECTIVE ACTION BOARD (CAB) ............
8
4. SYSTEM CHARACTERISTICS ....................
9
4.1 GENERAL ...................................
9
4.2 RELIMINARY REVIEW PROCESS ................ 9
4.3 MATERIAL REVIEW BOARD (MRB)
MEMBERSHIP ................................
9
4.4 MRB AUTHORITY AND RESPONSIBILITIES ........ 10
4.5 DISPOSITION OF NONCONFORMING
MATERIAL DURING MRB ...................... 10
4.6 IDENTIFICATION OF NONCONFORMING MATERIAL .. 11
4.7 SEGREGATION OF NONCONFORMING MATERIAL ..... 11
5. NONCONFORMING MATERIAL DOCUMENTATION ...... 12
5.1 GENERAL ................................... 12
6. DEVIATIN/WAIVER .......................... 13
6.1 DEFINITION ................................ 13
6.2 Request For Deviation/Waiver .............. 13
7. ACCEPTANCE OF NONCONFORMING MATERIAL ...... 14
APPENDIX A: "Flow Chart"
APPENDIX B: "Nonconormance Report"
APPENDIX C: "Request for Deviation/Waiver"
APPENDIX D: "MRB Report"…86…1 …02… …02… …02… …02…
1̲ ̲ ̲S̲C̲O̲P̲E̲
This standard defines the characteristics of a system
for handling of nonconforming material.
The system comprises:
- Identification of all material which does no meet
requirements.
- Segregation or control of this material to prevent
its unauthorized use or shipment.
- Identification and correcting conditions which cause
nonconforming material.
- Corrective actions to prevent the reissue of nonconforing
material.…86…1 …02… …02… …02… …02…
2̲ ̲ ̲A̲P̲P̲L̲I̲C̲A̲B̲L̲E̲ ̲A̲N̲D̲ ̲R̲E̲F̲E̲R̲E̲N̲C̲E̲ ̲D̲O̲C̲U̲M̲E̲N̲T̲S̲
A̲P̲P̲L̲I̲C̲A̲B̲L̲E̲ ̲D̲O̲C̲U̲M̲E̲N̲T̲S̲
a) AQAP-1
NATO Quality Control System Requirements for Industry
b) PAD/PRC/0005
Corrective Action Procedure
c) QA/PLN/0005
Configuration Management Plan
R̲E̲F̲E̲R̲E̲N̲C̲E̲D̲ ̲D̲O̲C̲U̲M̲E̲N̲T̲S̲
a) MIL-STD-1520A
Corrective Action and Disposition System for
Nonconforming Material
b) MIL-STD-480
Configuration Control-Engineering Changes,
Deviations, and Waiers
3̲ ̲ ̲D̲E̲F̲I̲N̲I̲T̲I̲O̲N̲S̲
3.1 G̲E̲N̲E̲R̲A̲L̲
The following definitions particularly apply to the
nonconformance handling system.
3.2 N̲O̲N̲C̲O̲N̲F̲O̲R̲M̲I̲N̲G̲ ̲M̲A̲T̲E̲R̲I̲A̲L̲
Any item, part or product with ne or more characteristics
which deviate from the requirements specified in the
contract, specification, drawing or other approved
product description.
3.3 M̲I̲N̲O̲R̲ ̲N̲O̲N̲C̲O̲N̲F̲O̲R̲M̲A̲N̲C̲E̲
A nonconformance to the requirements specified in the
contract, spcification, drawing or other approved product
description which does not adversely affect:
a) Performance
b) Durability
c) Reliability
d) Interchangeability
e) Effective use or operation, repairability
f) Weight or appearance (where a factor
g) Health or safety of user personnel
3.4 M̲A̲J̲O̲R̲ ̲N̲O̲N̲C̲O̲N̲F̲O̲R̲M̲A̲N̲C̲E̲
A nonconformance which affects the points a) through
g) and which cannot be eliminated by rework or reduced
to a minor NC by repair in accordance with para. 3.8
or 3.11. Final deision for acceptance of material containing
major nonconformances cannot be made by MRB. Acceptance
will require customer approval on the "Request for
Waiver/Deviation" form (Appendix C).…86…1 …02… …02…
…02… …02…
3.5 P̲R̲E̲L̲I̲M̲I̲N̲A̲R̲Y̲ ̲R̲E̲V̲I̲E̲W̲ ̲(̲P̲R̲)̲ ̲A̲C̲T̲I̲O̲N̲
The action taken by appointed Quality Control personnel
when a nonconformance is found during production or
incoming inspection and referral tothe Material Review
Board for disposition is not warranted.
3.6 M̲A̲T̲E̲R̲I̲A̲L̲ ̲R̲E̲V̲I̲E̲W̲ ̲B̲O̲A̲R̲D̲ ̲(̲M̲R̲B̲)̲
A board consisting of representatives of all departments
necessary to disposition nonconforming material referred
to them.
3.7 R̲E̲W̲O̲R̲K̲E̲D̲ ̲M̲A̲T̲E̲R̲I̲A̲L̲
Mterial that was nonconforming, but has been subjected
to a planned manufacturing process that restores all
nonconforming characteristics to the requirements specified
in the contract, specification, drawing or other approved
product description.
3.8 R̲E̲P̲A̲I̲R̲E̲D̲ ̲M̲A̲T̲E̲R̲I̲A̲L̲
Nonconforming material presented for acceptance after
it has been subjected to a planned manufacturing process
designed to reduce, but not completely eliminate the
nonconformance.
Prior to performing the repair, the associted repair
procedure has to be approved by the Material Review
Board.
Any repair method shall include the requirements for
re-inspection of the material.
3.9 S̲C̲R̲A̲P̲
Nonconforming material that is not usable and cannot
be economically reworkedor repaired.…86…1 …02… …02…
…02… …02…
3.10 "̲U̲S̲E̲ ̲A̲S̲ ̲I̲S̲"̲ ̲M̲A̲T̲E̲R̲I̲A̲L̲
Material with minor nonconformances presented to and
accepted by the MRB when the material is determined
to be satisfactory for its intended purpose.
3.11 S̲T̲A̲N̲D̲A̲R̲D̲ ̲R̲E̲P̲A̲I̲R̲ ̲M̲E̲T̲H̲O̲D̲ ̲(̲S̲R̲M̲)̲
A technique approved by the Material Review Board for
repairing a nonconformance when it has been demonstrated
that the technique, properly applied, will result in
an adequate and cost-effective method for dispostioning
the nonconformance.
3.12 C̲O̲R̲R̲E̲C̲T̲I̲V̲E̲ ̲A̲C̲T̲I̲O̲N̲ ̲B̲O̲A̲R̲D̲ ̲(̲C̲A̲B̲)̲
A board consisting of management representatives with
the responsibility and authority to assure that causes
of nonconformances are identified and corrective actions
are effected y responsible managers.…86…1 …02… …02…
…02… …02…
4̲ ̲ ̲S̲Y̲S̲T̲E̲M̲ ̲C̲H̲A̲R̲A̲C̲T̲E̲R̲I̲S̲T̲I̲C̲S̲
4.1 G̲E̲N̲E̲R̲A̲L̲
The system is established to identify, segregate (or
control if segration is not practical) and properly
dispose the nonconforming materal and assure positive
corrective action to preclude or reduce the rate of
nonconformances. Nonconformance flow is shown in the
flow-chart Appendix A.
4.2 P̲R̲E̲L̲I̲M̲I̲N̲A̲R̲Y̲ ̲R̲E̲V̲I̲E̲W̲ ̲P̲R̲O̲C̲E̲S̲S̲
When material is initially found to be nonconforming,
it may e examined by the Quality Control personnel
to determine if the nonconformance:
a) Can be reworked
b) Must be scrapped because it is obviously unfit
for use and cannot be economically repaired.
c) Can be repaired by standard repair methods (SM)
d) Will be returned to the supplier.
e) Meets none of the above criteria and will be referred
to the MRB.
4.3 M̲A̲T̲E̲R̲I̲A̲L̲ ̲R̲E̲V̲I̲E̲W̲ ̲B̲O̲A̲R̲D̲ ̲(̲M̲R̲B̲)̲ ̲M̲E̲M̲B̲E̲R̲S̲H̲I̲P̲
The MRB shall be chaired by a representative of the
quality control organization and sall include, as required,
personnel representing other organizations necessary
to determine appropriate disposition. As a minimum,
the MRB will include:
a) Quality Control Representative (Chairman)
b) If material originates in-house:
One reprsentative from the organization responsible
for the design of the product.…86…1 …02… …02… …02…
…02…
c) If material originates outside:
One representative from the organization responsible
for the procurement.
d) One representative from the organization(s) which
utilizes the aterial for production or integration
into higher order units.
e) Customers Quality Assurance Representative at the
Customers option.
MRB members shall be selected on the basis of their
technical competance. It shall be assured, that MRB
member know the requirements of this standard. MRB
members may call upon other personnel for technical
advise. A list of authorized MRB members is located
in the PA department.
4.4 M̲R̲B̲ ̲A̲U̲T̲H̲O̲R̲I̲T̲Y̲ ̲A̲N̲D̲ ̲R̲E̲S̲P̲O̲N̲S̲I̲B̲I̲L̲I̲T̲I̲E̲S̲
The MRB shall investigate, in suficient depth, all
nonconforming material referred to them to determine
proper disposition and necessary corrective actions.
Only minor nonconformances can be disposed by MRB.
The MRB shall dispose of nonconforming material in
accordance with pararaph 4.5.
MRB approval can only be granted if all the voting
members agree.
4.5 D̲I̲S̲P̲O̲S̲I̲T̲I̲O̲N̲ ̲O̲F̲ ̲N̲O̲N̲C̲O̲N̲F̲O̲R̲M̲I̲N̲G̲ ̲M̲A̲T̲E̲R̲I̲A̲L̲ ̲D̲U̲R̲I̲N̲G̲ ̲M̲R̲B̲
All material with minor nonconformances not dispositioned
in preliminary review shall be dispositioned by MRB
asfollows:
a) Scrap
b) Repair to a Standard Repair Method (SRM)
c) Rework
d) Return to Vendor…86…1 …02… …02… …02… …02…
e) Use as is
f) Repair (No SRM exists)
g) Propose a Modification (Ref. QA/PLN/0005)
Nonconformances classified as major will be processed
as described in paragraph 6.
4.6 I̲E̲N̲T̲I̲F̲I̲C̲A̲T̲I̲O̲N̲ ̲O̲F̲ ̲N̲O̲N̲C̲O̲N̲F̲O̲R̲M̲I̲N̲G̲ ̲M̲A̲T̲E̲R̲I̲A̲L̲
The nonconforming material is identified by a special
tag deviating from the normal tag used for accepted
material.
Example of such a tag is included in fig. 4.6-1
4.7 S̲E̲G̲R̲E̲G̲A̲T̲I̲O̲N̲O̲F̲ ̲N̲O̲N̲C̲O̲N̲F̲O̲R̲M̲I̲N̲G̲ ̲M̲A̲T̲E̲R̲I̲A̲L̲
Nonconforming material waiting for disposition is segregated
in a bonded area (room or cabinet) if practical with
regard to physical limitations.…86…1 …02… …02… …02… …02…
5̲ ̲ ̲N̲O̲N̲C̲O̲N̲F̲O̲R̲M̲I̲N̲G̲ ̲M̲A̲T̲E̲R̲I̲A̲L̲ ̲D̲O̲C̲U̲M̲E̲N̲T̲A̲T̲I̲O̲N̲
5.1 G̲E̲N̲E̲R̲A̲L̲
The nonconformance documentation is necessary to permit
efficient retrieval of:
a) Summarization
b) Knowledge of previus dispositions
c) Corrective action monitoring
Anybody who encounters a nonconformance event shall
as soon as possible fill in a nonconformance report
form and hand it over/send it to a Quality Control
representative for Preliminary Review disosition.
The form "Non Conformance Report" is shown in Appendix
B.
Material which requires MRB approval shall be documented
by QC on the Material Review Board Report (MRBR), Appendix
D.
QC is responsible for proper distribution and filing
of CRs and MRBRs and for initialization of necessary
actions.
A copy of the approved MRBR is sent to the Quality
Engineering Manager for information to the Corrective
Action Board (CAB).…86…1 …02… …02… …02… …02…
6̲ ̲ ̲D̲E̲V̲I̲A̲T̲I̲O̲N̲/̲W̲A̲I̲V̲E̲R̲
6.1 D̲E̲F̲I̲N̲I̲T̲I̲O̲N̲
A waiver is the act whereby the customer or the customer's
representative authorizes the utilization or supply
of a material with major nononformances in its current
condition.
A deviation is the act whereby the customer or the
customer's representative authorizes the utilization
or supply of material with major nonconformances before
the start of the production activities.
6.2 R̲q̲u̲e̲s̲t̲ ̲f̲o̲r̲ ̲D̲e̲v̲i̲a̲t̲i̲o̲n̲/̲W̲a̲i̲v̲e̲r̲
The procedure for processing a Deviation/Waiver is
as specified in CR QA/PLN/0005 "Configuration Management
Plan".
The form "REQUEST FOR DEVIATION/WAIVER" is shown in
Appendix C.…86…1 …02… …02… …02… …02…
7̲ ̲ ̲A̲C̲C̲E̲P̲T̲A̲N̲C̲E̲ ̲O̲F̲ ̲N̲O̲N̲C̲O̲N̲F̲O̲R̲M̲I̲N̲G̲ ̲M̲A̲T̲E̲R̲I̲A̲L̲
Nonconforming material can only be accepted by the
customer or the customers representative if the following
conditions have been met:
- The material has no other discrepancy than the
one reported on the MRBR-Form or the Request for
Deviation/Waive Form.
- The MRBR-Form has been approved in writing by the
appointed CR representatives, and corrective actions
indicated have been verified.
