Control of Non-Conforming Product
1.1.
The following definitions are important for a clear understanding of this procedure:
1.1.1.
“Non-conforming product” is any product, at any point along its life cycle, which is found to not conform to requirements. These requirements may be customer requirements, design requirements, statutory/regulatory requirements, or any other requirement deemed by Lyra (Pvt) Ltd “Nonconforming Product” is referred to herein as “NCP”.
1.1.2.
“Rework”. Parts may be “reworked” when additional machining or processing is conducted without affecting the design of the part. Typically this means simply doing more of the already-approved processes or activities listed on the traveler (additional machining, etc.)
1.1.3.
“Repair”. Any work done on NCP which affects the original design is considered “repair” and is subject to the special controls defined in section 3. See below. Such work includes but is not limited to the adding welds to correct a problem, adding or removing material beyond design specifications, adding plating or metal finishing not originally included in the design specs, or adding any other materials (epoxy, patches, etc.) not provided for in the original design.
1.2.
While nonconforming product is typically found during an inspection or test, it can be discovered at any time, by any person or organization, including the customer, regulatory authorities, etc.
2.
CONTROLLING NCP
2.1.
Discovery and Reporting of NCP
2.1.1.
When NCP is discovered, the operator must report this immediately to the Production Manager.
2.1.2.
The Managing Director shall confirm if nonconformity exists, and if so document it on the Product Non-Conformance record (PNC).
2.1.3.
The NCP shall then be identified clearly to distinguish it from acceptable product, or product awaiting inspection or test. Red Trolley/Bucket.
2.1.4.
The NCP shall then be disposed. Disposition authority is granted to the following personnel:
·
Director
·
Managing Director
2.1.5.
The selection of these staff members has been made by top management, and is based on their role in the company, previous experience, and knowledge of Lyra (Pvt) Ltd’s processes and products.
2.1.6.
Possible dispositions are:
·
Accept as is
·
Repair (see special rules for repair below)
·
Rework
·
Scrap
·
Return to Vendor
2.1.7.
All repair or reworked product must be re-inspected, with the results recorded on Product Non-Conformance record (PNC)
2.1.8.
If “accept as is” will require the acceptance of the part which deviates from a customer’s design, the customer’s approval must be obtained and documented on the Product Non-Conformance record (PNC). In addition, when applicable, regulatory authority approval(s) may also be required to be obtained and recorded.
2.1.9.
The disposition, disposing authority and any subsequent work and re-inspection are to be recorded on the Product Non-Conformance record (PNC)
2.1.10.
The processing of NCP must take into consideration any actions necessary to contain the effect of the nonconformity on other processes or products.
3.
SPECIAL RULES FOR REPAIRS
3.1.
“Repair” is defined in section 1.2.3 above.
3.2.
Any repair affecting a customer designed part must be approved by the customer in advance.
3.3.
Repairs without customer approval are disallowed in all circumstances!
3.4.
All approvals must be documented and the records maintained with the part records.
4.
NONCONFORMANCE DATA ANALYSIS & TRENDING
4.1.
The Management Representative will present product quality trend data regularly to top management as part of periodic Management Review Meetings.
Note:
Optionally following records are maintained online at www.companycertification.com/lyra
·
Product/Service Non-conformance Record
·
Product/Service Non-conformance (PNC/SNC) Log