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General Highlights and Changes QAR Instruction

General Highlights and Changes QAR Instruction. Redefined, Enhanced and Separated One Book into two (2) DCMA NSEP Instructions; QAR and Program Management Grouped and combined requirements by process topic (2.3) Removed NOFORN classification – Web Accessible

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General Highlights and Changes QAR Instruction

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  1. General Highlights and ChangesQAR Instruction • Redefined, Enhanced and Separated One Book into two (2) DCMA NSEP Instructions; QAR and Program Management • Grouped and combined requirements by process topic (2.3) • Removed NOFORN classification – Web Accessible • Added under the Level 1/SUBSAFE Program • Deep Submergence Systems Program (DSSP) • Scope of Certification Program (SOC) • Fly By Wire (FBW) • Incorporated DLAR 8225.1 Enclosures 4. • Instruction now supersedes this enclosure

  2. General Highlights and ChangesQAR Instruction • Compliance-based Instruction. The granting of waivers or deviations from the mandatory requirements, as stated is not permitted at the District or Contract Management Office level. • This Instruction links customer expectations with DCMA processes and products. • Our customers have defined their expectations as – The delivery of hardware and associated deliverable data that is in compliance with all contract administrative, quality and technical requirements resulting in an increase in supplier first pass yield at customer Receipt Inspection Activities

  3. General Highlights and ChangesQAR Instruction • Process topics • Facility Surveillance and Inspection Plan (FSIP) (3.1) • Contract Receipt and Review (3.2) • Quality Assurance Letter of Instruction (QALI) and Letters of Delegation (LOD) (3.3) • Delegation of Government Source Inspection (GSI) (3.4) • Technical Review of Subcontract Purchase Order (3.5) • Product Audit/Inspection (3.6) • Material Certification Review Process (3.7) • Supplier Audit Program (SAP) (3.8) • Process Surveillance Program (3.9) • Quality System/NSEP Program Evaluations (3.10) • Corrective Action Program (3.11) • Quality Data Evaluation (QDE) (3.12) • Training Program (3.13) • Other NSEP Requirements [Related Processes and Guidance] (3.14) • Specific NSEP Program Requirements - Subsections 1(NNPP), 2 (NPM), 3 (L1/SS/DSSP/SOC/FBW), and 4 (NPP)

  4. General Highlights and ChangesQAR Instruction • Subsection 1 - Naval Nuclear Propulsion Program (NNPP) • Subsection 2 & 2A - Nuclear Plant Material (NPM) Program • Subsection 3 - Navy Level I (LI) Program, the Submarine Safety (SUBSAFE) Program • Subsection 4 - Navy Propulsion Program (NPP)

  5. General Highlights and ChangesQAR Instruction • Infrequent Suppliers • Breaks in NSEP Contracts • Low Complexity • Short term Contract Performance • Determined by the QAR and NSEP Monitor (may require NSEP Coordinator assistance) • Documentation and notification required • Minimum Requirements: • Contract Receipt and Review (3.2) • Quality Assurance Letter of Instruction (QALI) and Letters of Delegation (LOD) (3.3) • Delegation of Government Source Inspection (3.4) • Technical Review of Subcontract Purchase Order (3.5) • Product Audit/Inspection (3.6) • Process Surveillance Program (3.9) • Corrective Action Program (3.11) • Training and Qualifications (3.13.) • Other NSEP Guidance and Requirements (3.14.) as applicable • The applicable NSEP QAR Instruction Subsection

  6. 3.1 Facility Inspection and Surveillance Plan • A Facility Surveillance and Inspection Plan is prepared to identify the QARs overall plan to evaluate quality system and product related processes. • Updated semi-annually • Initial and semi-annual updates provided to NSEP customers for review and feedback • Pen/Ink Interim updates • Focus FSIP on: • Recurring manufacturing and process surveillance • Floor surveillance activities • Product inspection & re-inspection • Quality issues & concerns • Problem areas • New process • Process changes

  7. 3.1 Facility Inspection and Surveillance Plan • FSIP development dependent on: • QDE • SAP findings • Process Surveillance • Customer Requirements • Daily Walkthrough – documentation requirement removed but still recommended • FSIP Outline

  8. 3.2 Contract Receipt and Review • Facility and Contract Profile data (1770B) will be reported in accordance with the Supplier Quality Assurance Guidance, paragraph 1.4.2 with the applicable NSEP codes (N4, LI). • Alternate methods are allowed provided the developed system captures all of the NSEP contracts/Purchase Orders • Contract Review Format shall be used for documentation. Alternate forms are allowed provided the same type information is captured • No NSEP program specifics in EDW or RAMP. Ensure CMO functional element responsible for scanning and entering data into EDW is aware of this requirement.

  9. 3.2 Contract Receipt and Review • When NSEP contract identifiers are noted at time of initial contract review and if they are new to the facility, the QAR must advise their supervisor and their CMO NSEPM. • QA Only Post Award Conferences must be conducted when: • New contractor • Infrequently active contractor • Contractor exhibits adverse quality/performance trends • First article or pre production required • Requested by the PCO or delegating activity • The QAR should notify the PCO, ACO and Prime QAR (if working to a delegation) that a “Quality Only” Postaward has been scheduled with the supplier and ascertain if they want to participate

  10. 3.3 QALIs and LODs • No real changes. Section Highlights: • Completion of Mandatory Inspection Requirements Form • Customer notification of A) MI cannot be performed. B)MI was not performed. • Completion of Contract Review checklist

  11. 3.4 Delegation of Government Source Inspection • Contractor’s system provides QAR subcontracts for review • Still No automatic delegations • All LODs shall include all applicable requirements identified in the original QALI or LOD as well as reference the QAR Instruction and the applicable Subsections. Will also contain: • All oversight requirements • Frequency of performance • Request for all Level II, III, IV CARs • Acknowledgement within 30 days • Completion of Mandatory Inspection Requirements Form • QAR Certification dates/evidence • Standard Letter of Delegation

  12. 3.4 Delegation of Government Source Inspection • When deficient material is received from a subcontractor on a purchase order where GSI is invoked (regardless of whether the deficiency was part of the GSI request), the delegating QAR will verify the condition and notify the cognizant CMO NSEPM or DNSEPC and the QAR cognizant of the subcontractor. • OCONUS requirements: • Customer Notification • LOD development w/ NSEPM or DNSEPC • LOD provided to DCMAI • Prime QAR copied for re-delegation to Host Nation • No transmittal of NOFORN or Export Control documents • No “repackaging” of NOFORN Information • Performed by U20 certified QARs

  13. 3.5 Technical PO Review • Separate from PO review for GSI • Monthly reviews shall confirm inclusion of the correct and complete contract administrative and technical requirements to ensure proper flow down of technical and quality requirements. • A minimum of 5% or one per month, which ever is greater, of the subcontract purchase orders shall be selected for review. Those reviewed shall consist of PO for: • Raw Material • High Strength heat treatable materials • Weld filler material • Machining • Heat treat • NDT • Plating • Assembly • Welding • Other special processes • Testing

  14. 3.5 Technical PO Review • Records must include: • Person performing the review • Date of review • Subcontract purchase order number • Subcontractor • Material, process, or product • Accept/reject (if rejected – traceability to the CAR issued) • GSI delegated • Acknowledgement received • Evidence of Completion of MIs/ORs at the sub-tier level

  15. 3.6 Product Audit/Inspection • Independent verification of specific product or process characteristics. • Copies of NSEP Instructions, QALI/LOD or FSIP shall not be provided to the contractor • Minimize the use of contractor hold/notification points • Use only contractor Inspection equipment • Coordination with customer for Joint Source Certification • Annotation with DD 1902 NDT Certification card number on all related NDT documents

  16. 3.6 Product Audit/Inspection • Documentation Tool (E-1711) • Minimum documentation requirements: • Mandatory inspection performed (QALI/LOD identifier) • Contract/purchase order number • Description of component • Part number and revision number • Serial/lot and/or heat number, as applicable • Date of Inspection • Supplier procedure used [if applicable] • Lot and sample sizes • Acceptance or rejection (if reject – traceability to the CAR issued) • Name of individual performing inspection [first initial and last name or unique individual code]

  17. 3.7 Material Certification Review Process • Material Certification Review is the process of assuring associated test and inspection reports support the product integrity (ROTIs) • Material Certification review description link • Records maintained with Product Audit/Inspection records identifying specific attributes verified • Development of Checklist for use as Best Practices

  18. 3.8 Supplier Audit Program (SAP) • Periodic in‑depth evaluations of important quality assurance and manufacturing and inspection processes in an effort to reduce the number of repetitive audits at critical Navy contractors. • QARs cognizant of active NSEP contractors will implement the Supplier Audit Program, report audit results, and perform audit follow up efforts on corrective action requests as defined. • QARs cognizant of Principal NSEP contractors will perform and report SAP audits only when delegated by the customer or SAP participant. Prior to performing any SAP audit at a Principal NSEP contractor, NSTR-PGH shall be contacted, for direction

  19. 3.8 Supplier Audit Program (SAP) • Still requires PDREP Access • Same Web addresses • Updated SAP Instruction Guide, Auditor’s Guide, Process Audit Cover Sheet, Process Audit Checklists and Cage Code Supplier Name information • Auditor requirements found at SAP Web site and Chapter 6 of NAVSO-P-3683 • Same 28 Process Audits • Checklist available in Word

  20. 3.8 Supplier Audit Program (SAP) • All process audits to be done Initially. • Re-Audits done as follows: • The following six processes shall be re-audited every two years: • 6. Material Control (Including LI/SS) • 9. Control of Suppliers/Subcontractor’s Flow Down of Customer Requirements • 15. Supplier Control of Objective Quality Evidence and Material Traceability • 16. Packaging and Preservation • 17. Final/Ship out Inspection • 20. Customer Contract/Purchase Order Control • Remaining process audits shall be re-audited based on a Risk based approach using OQE. • Interim process monitoring using 3.9 Process Surveillance

  21. 3.8 Supplier Audit Program (SAP) • Re-audit all or the applicable portion of a SAP process when significant changes occur. • ^designate processes that require notification to the Lead SAP Activity or Delegating Activity, prior to performing the audit, when the processes are sub delegated by the prime QAR • 8 Special Process • * designate the QAR and subcontractor QARs must flow down the performance of these audits to the contractor who is actually performing the process • 15 Process audits • Metallurgical/Chemical Laboratory Testing - will identify testing capability contractors

  22. 3.8 Supplier Audit Program (SAP) • SAP Documentation • Upon FSIP development, SAP audits are identified as “pending” • Provide narratives identifying reviewed items, results, and CARs • Checklist (Word) will be attached to the Summary report • Delegated SAP reports will be forwarded to the customer delegating activity • SAP Lead activities when delegating SAP audits are responsible for database input • Subcontractor QAR in response to a LOD shall input results to the Database under the Subcontractor Cage Code • Prime QAR inputs audit as “pending” under Prime Cage Code • Completion of Mandatory Inspection Requirements form shall be returned to the Prime QAR as notification of SAP audit completion

  23. 3.8 Supplier Audit Program (SAP) • QARs must participate in SAP audits for contractors on the current SAP Supplier List • When unable, review SAP database for results or have a copy provided by the Lead Activity • Customer notification for any hardware deficiencies or loss of material traceability • Corrective Actions: • Level I reported in “Auditor’s Overall Assessment’ section • Assign appropriate level of CAR with contractor replies due NLT 30 days • Follow-up NLT 30 days upon CAR reply • Evaluate CA effectiveness • CAR updates and close-out must be posted to the SAP database

  24. 3.9 Process Surveillance • Process Surveillance is the periodic recurring, direct observation of contractor personnel performing manufacturing, inspection, and test operations • Process Surveillance Program deployment involves: • Identification of applicable processes • Scheduling • Recording results • Identification • Incorporated manufacturing and testing NSTR 86.1 processes as listed in 3.9.4 • SAP processes • Quality System processes listed in 3.9.5 • QAR identified

  25. 3.9 Process Surveillance • Scheduling • High Risk more frequent than Moderate • Minimum surveillance – NTE 3 months or once during contract/PO life • All attributes and variables ( operators, inspectors) to be evaluated NTE one year

  26. 3.9 Process Surveillance • Records shall include: • Process Reviewed • Contract/Purchase Order Number • Description of Component • Part and Serial Number • Date • Supplier Procedure or Work Instruction • Accept or Reject (if rejected identify serial number of CAR issued) • Name of Individual performing surveillance (first initial and last name or unique individual code) • Contractor personnel performing process • Brief narrative of oversight action/activity performed including the following: • Product/process attributes verified • Other pertinent information • Rationale for CAR, if applicable

  27. 3.10 Quality System and NSEP ProgramEvaluations • Quality System and NSEP Program evaluations are performed at NSEP contractor facilities on specific quality systems or unique NSEP program documents/specifications • Quality System Evaluations (QSE) - performed on those contractual higher-level contract requirements (FAR 46.202-4) quality systems/processes that are not evaluated under the SAP (3.8) • Mil-I 45208 Inspection System • Mil-Q-9858 Quality System • ISO 9000 Quality System Series Documents • ISO 9000 Quality System Series Documents and any Customer Imposed Supplemental Technical Requirements (STRs) that apply.

  28. 3.10 Quality System and NSEP Program Evaluations • Unique NSEP Program processes: • MIL-STD-767, Military Standard Control of Hardware Cleanliness • MIL-STD-2132, Non-Destructive Examination Requirements for Special Applications • MIL-STD-2041, Military Standard Control of Detrimental Material • MIL-P-23199, Packaging for Special Components • NAVSEA 0900-070-6010, Material Control Standard, (Nuclear) • NAVSEA 250-1500-1, Welding Standard • NSTR-99, Qualification Examination Requirements for NDT Personnel • MIL-STD-1308, Material Processing for Special Components • STR 500, Supplementary Technical requirements, Valve General Technical Requirements • STR-505, Supplementary Technical Requirements, Material Identification and Control Requirements for Manufacturers of Level I Material • MCS-6, Standard for Control of Material • QRC 82 Quality Program Requirements • ISR-I Inspection Systems Requirements • LSC-2, Special Repair Part Supplier Control Requirements • Other Contract specified requirements

  29. 3.10 Quality System and NSEP Program Evaluations • Determine applicable requirements • QSE conducted: • Based on objective data • Sample verification of key system elements authorized to validate 3rd party audits • Risk rate to prioritize effort • Unique NSEP requirements: • Procedure review • Audit to procedures

  30. 3.10 Quality System and NSEP Program Evaluations • Audit planning identifies applicable requirements and then development of an audit plan. • In lieu of a written plan, the QAR may also highlight those sections of contractor procedures of contract requirements that will be verified during the audit • Records • Highlighted documents will be retained as part of audit record • List of those actions taken to verify contractor compliance • Identification of any applicable CARs

  31. 3.11 Corrective Action Program • No Major Changes • Reiterations: • Level I records maintained • Level II shall require: • Root cause of the non-conformance • Extent of nonconformance of work in-progress and shipped product • Specific actions planned to resolve the cause of the nonconformance • Specific action (s) taken to resolve the nonconformance • Specific actions to be taken to verify the effectiveness of the corrective action taken • Specific dates for completing each action • Level III require proper notifications to internal and external customers • Level IV requires written customer consent prior to GSI discontinuance

  32. 3.12 Quality Data Evaluation • Quality Data Evaluation is a tool to assess contractor performance and its outcome is used to direct the QAR’s in-plant effort toward products and processes that present the highest risk • The design of the system is left to the discretion of the QAR; however, a quality data evaluation system should contain several basic elements that include: • Definition of the data to be collected • Method and frequency of data evaluation • Record of the data evaluation results • Records of specific actions to be taken

  33. 3.12 Quality Data Evaluation • Sources of Quality Data – 3.12.4 • The method to sort and display the quality data for evaluation is left to the discretion of the QAR • Quality data evaluation will be performed, as a minimum, every (3) months in support of developing/revising the FSIP • Records must include a synopsis of findings and an analysis of the evaluation • QAR’s records of QDE must contain the following data as a minimum: • Date of evaluation • Data evaluated • Person performing evaluation • Findings and results of evaluation • Recommendations made or actions to be taken • Results of quality data evaluation will be recorded in the FSIP along with actions planned to be taken by the QAR.

  34. 3.13 Training and Qualifications • QAR training requirement: • DAWIA II in QA • Commodity • NSEP Training U20 • Certification of contractual NDT methods • Redefined Training Certification requirements: • Expanded/Combined U20 and R70 into 3 part, 120 hour course: • U20A, NSEP Concepts/History/Application • U20B NSEP Instruction Overview • U20C Material Certification Review Process • Need all 3 courses for DD250 execution • Provided CBT for annual SUBSAFE Awareness Training • U21 expanded to include NPM QARs • Refresher U20B and C for U20 certifications attained prior to 1995

  35. 3.14. Other NSEP Guidance and Requirements • RAMP will consist of only the following inputs: • Contractor FSCM, address and point of contact • Critical contractor designator [s] • Overall risk rating of at least Moderate for Performance • Principal NSEP Contractors shall be risk rated as “High” • Overall narrative statement (in general terms only, no program specifics allowed) that the product supplied has a critical application • Pre-Award Survey - PAS shall be performed in accordance with DCMA Pre-Award Survey Guidance. • Fraud and Falsification/Deliberate Malpractice/Government Investigation: • Proper and immediate notification • NO QAR independent or contractor investigations

  36. 3.14. Other NSEP Guidance and Requirements • Deficiency Reports - All NSEP DD 1227 responses to NSEP DRs will be routed to the CMO Commander for final approval. • Records: • Electronic records require periodic back-up • Unless otherwise specified, retain records for three years • Control of NSEP Material: • NSTR-2001 will provide instruction on the control of NNPI and NOFORN documents • Contract Clarification – Use DD1716 • Use for Part Number Buys, item description • Direct Lines of Communication • Unfettered • Updating voice mail and e-mails daily

  37. 3.14. Other NSEP Guidance and Requirements • Alternate Release Procedures (ARP) on any NSEP work is strictly prohibited • Wide Area Work Flow (WAWF) is being implemented • PLAS Reporting: Process code 068 and its sub-codes must be used as required when performing the sub-processes under the 068 code. Otherwise the typical and existing SQA process codes should be used in conjunction with the applicable NSEP Program Code (i.e. Contract review of a Nuclear Plant Material contract would be input to PLAS as Process Code 031A and Program Code NP041). • 1.1 Program Code NP033, Naval Nuclear Propulsion Program • 1.2 Program Code NP040, Level I/SUBSAFE • 1.3Program Code NP041, Nuclear Plant Material • 1.3.1 Use Program Code NP041 for NSTR-2000 delegations received at other facilities. • 1.4 Program Code NP042, Navy Propulsion Program • 1.5 Program Code NP043, Deep Submergence Systems Program/Scope of Certification

  38. SUBSECTION 1NAVAL NUCLEAR PROPULSION PROGRAM (NNPP) • Program Guidance provided in NSTR-2000 • SAP – prior coordination with NSTR • DCMA Initiatives require prior NSTR consent • Management Control Reviews require prior coordination with HQ NSEPM and NSTR

  39. SUBSECTION 2NUCLEAR PLANT MATERIAL (NPM) • Same contract identifiers • DLA contracts no longer considered NPM • Subsection 2A – Standard NPM QALI/MI requirements • Attached QALIs no longer automatic • Applicable to part number buys containing NO IRPOD • Return Standard QALI/MI form for all X4 SMIC valve and valve repairs • Regardless of QALI absence/presence: • All CDRL items shall be verified for compliance • Still require U20 certified QAR • QAR must posses MIs when performing surveillance

  40. SUBSECTION 3LEVEL I / SUBSAFE (LI/SS) THE DEEP SUBMERGENCE SYSTEMS PROGRAM • Addition of SMIC contract identifiers for DSSP orders • DO • D4 • DG • Addition of SC12-34 for EB and NGNN • Incorporated and changed Attachment 6 “Minimum Mandatory Inspection Requirements”. These requirements shall always be applied to LI/SS/DSSP orders • Established Table 1 “Sampling Plan” when sampling is not contractually specified. Adjusted sample sizes to accommodate/incorporate -7010 • Established 1.0% AQL • 100% remains for Documentation, Material ID, Material Verification and RT

  41. SUBSECTION 4NAVY PROPULSION PROGRAM (NPP) • No major changes • QAR must provide surveillance as required by QALI/LOD • Inspection documentation forms available @ http://spt.dcmdw.dcma.mil • Pitchometer process review to be coordinated with NPP Lead Agent • QAR must attend at least once every 5 years the Navy Propeller Refresher Training Course provided by the Lead Agent • RODs and PQDRs copies provided to Lead Agent • Records maintained for 10 tears

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