Trinity Operating Procedures - TOPs

TOP-NOCON: Handling of Non-Conforming Product

Rev: 2/22/2023

Scope: This procedure covers the handling/storage of all nonconforming forged and/or machined product returns as well as discrepant forged or machined part disposition.

Procedure:

STEP	WHO	WHEN	INFO TO USE	WHAT TO DO
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; Blueprint(s); tags on parts containers; own judgment	Tag any questionable parts or tubs with a Red Disposition Tag clearly and visually identifying who, when and why for the hold. Have parts immediately moved to MRB/Customer Return Area*. If production Traveler or QC Print identifies parts as Nuclear or states 10CFR21 (note sections 21.21 thru 21.62) applies, notify QA Manager immediately. Note: A red tag denotes whether the parts are on hold or need rework and should be marked accordingly. The tag shall be signed and dated each time the status is changed.
2	Any team member that has tagged parts as non-conforming	Once parts have been tagged and placed in the MRB Area.	Production Traveler and contents of QC Inspection Folder; Blueprint(s); Disposition Tag	Fill out a Rejection Notice. This notice is to be emailed to the QA Manager, QC Manager, and any other shop employees involved with the parts as a notification. If part is identified as Nuclear/10CFR21 applicable, make sure it is identified as such on the rejection notice.
3	Material Review Board (MRB): QC Manager, QA Manager, Manufacturing Manager	As needed	Contents of QC Inspection Folder; Production Traveler,  Blueprint; discussions with other managers or customer; Rejection Notice; 10CFR21 requirements if applicable	Review Rejection Notice; determine disposition of the part/tub and tag accordingly, bringing in other team members as deemed appropriate (especially include VP-Quality & Engineering and QA Manager for difficult problems); ensure that the Rejection Notice is filled out per Board's plan;
3A	Material Review Board (MRB): QC Manager, QA Manager, Manufacturing Manager	If non-conforming parts are found acceptable		Fill out rejection form accordingly and reply to original email with a copy of the rejection form. Remove red Disposition Tag and process parts according to Traveler;
3B	Material Review Board (MRB): QC Manager, QA Manager, Manufacturing Manager	If non-conforming parts are found to need rework		Fill out rejection form accordingly and reply to original email with a copy of the rejection form. Mark the red Disposition Tag denoting specific instruction for reworking. 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 Assistant or Machining Department Clerk. Note: The tag shall be signed and dated each time the status is changed.
4	Material Review Board (MRB): QC Manager, QA Manager, Manufacturing Manager	If non-conforming parts are found to need customer acceptance/Rejection.		Place Job Order on hold in M2M. Notify MRB Members by email; notify QA Manager, QC Manager and Customer Service Representative by email
4A	Material Review Board (MRB): QC Manager, QA Manager, Manufacturing Manager	If non-conforming parts are found acceptable by the customer.	Customer Email; Waiver Response	Fill out rejection form accordingly and reply to original email with a copy of the rejection form. Add Green "Ready to Ship" Disposition Tag for a visual indicator of status and put Production Floor Traveler back into circulation and take parts off hold in M2M
4B	Material Review Board (MRB): QC Manager, QA Manager, Manufacturing Manager	If the customer rejects non-conforming parts.	Customer Email; Waiver Response	Fill out rejection form accordingly and reply to original email with a copy of the rejection form. Notify team members that parts will need to be scrapped and a new Job Order needs to be set up in M2M.
5	Any supervisor or other team member responsible for verifying conformance of parts	Once parts have been dispositioned by MRB.	Rejection Notice	Move parts out of the MRB/Customer Returns area to the appropriate location.
5A	Any supervisor or other team member responsible for verifying conformance of parts	Parts determined to be acceptable and are properly tagged.	MRB decision; Final Inspection Report; Blueprint(s)	Move parts to the Disposition Area until JO is resumed
5B	Any supervisor or other team member responsible for verifying conformance of parts	Parts determined to need rework and are properly tagged.	MRB decision; Final Inspection Report; Blueprint(s)	Move parts to the Disposition Area until rework is begun.
5C	Any supervisor or other team member responsible for verifying conformance of parts	Parts pending customer feedback on acceptance or rejection.	MRB decision; Final Inspection Report; Blueprint(s)	Parts will remain in the MRB/Customer Return Area until disposition is received from the customer.
5D	Any supervisor or other team member responsible for verifying conformance of parts	Parts determined to be scrap and are properly tagged	MRB decision; Final Inspection Report; Blueprint(s)	Parts are to be scrapped physically and systemically. Verify de-mil or destruction of faulty parts as mandated by the router. If the router does not have a de-mil or destruction instruction, the part must be put in the designated scrap part bin. All scrap parts must be put in specified scrap parts bin.
6	QA Assistant	All other scrap parts	Scrap vendor certifications, periodic audit of scrap vendor facilities.	Verify that all scrap parts are rendered unusable.
7	Material Review Board (MRB): QC Manager, QA Manager, Manufacturing Manager	Bi-Monthly	Rejection Notice’s; MRB Area	Meeting held to review both customer return status and current parts in the MRB/Customer Returns and Disposition Areas.
***The following lines are applicable if a defect exists under 10CFR Part 21 for any nuclear orders. ***
1	QA Manager	When receiving a rejection notice for parts where 10CFR21 applies	Rejection Notice	Determine if parts in current condition could create a substantial safety hazard, or if previously shipped parts could have same defect or deviation; per (10 CFR part 2); notify customer within 2 days of discovery.
2	QA Manager	If determined that parts could create a substantial safety hazard		Notify customer within five working days of determination of inability to perform the evaluation.
3	QA Manager	Once determined non-conforming part is applicable to 10CFR21		Ensure that all documentation is properly identified as 10CFR21. This is to include by not limited to the Rejection Notice and Tags.
4	QA Manager	Whenever a non-conforming 10CFR21 part is identified		Maintain a log of all recorded 10CFR21 non-conforming parts.

*MRB/Customer Return Area must both be clearly marked and identified. This could include temporary areas defined by agreement of QC Manager, Machining Department Supervisor and  Post Forge Supervisor. Primary, Critical and Flight Safety Parts must be stored in a secured MRB location designated by the QA Manager until dispositioned by the customer.

Revision history:

Release Date	Description of Change	Owner	Approver
12/06/2017	Updated to comply with revised Quality Manual and new TOPs format.	Tim Ellis	Todd Sheppard
2/27/2019	Step 5, instruction for scrap part bin. Step 6, verifying all parts rendered unusable.	Tim Ellis	Todd Sheppard
2/27/2020	Updated tagging procedures and clarified MRB for both forge & machine	Todd Sheppard	Dustin Jump
4/1/2020	Updated MRB term & frequency.	Dustin Jump	Todd Sheppard
2/8/2023	Updated types of tags used and correct usage of them. Remove QC Supervisor and add QC Manager.	Dustin Jump	Todd Sheppard
2/22/2023	Revised entire TOP to reflect current process, Added addition 10CFR21 section	Dustin Jump	Todd Sheppard

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