第6章-不一致品的糾正

1、JSSN江蘇世能化工設(shè)備有限公司QUALITY CONTROL MANUAL質(zhì)量控制手冊DOC.NO.：JSSN/SC-01文件號Edition版本： 2014Shop Construction and Field Site Assembly of Power Boilers and Pressure Vessels & Parts and Pressure Piping in accordance with ASME Boiler and Pressure Vessel Code Section I, Section VIII Division 1 and ASME Code B31

2、.1按ASME規(guī)范第I卷、第卷第1冊及B31.1在工廠建造與現(xiàn)場安裝鍋爐壓力容器及其部件和壓力管道Revision No修訂號.：0Correction of Nonconformities不一致品的糾正Section章：6Page：6 of 6 第6頁 共6頁 6.0、Purpose目的This Section describes the disposition procedure of nonconformities found at receiving inspection and during fabrication of Code Items.本章描述了在材料驗(yàn)收及規(guī)范產(chǎn)品的制造過程

3、中發(fā)現(xiàn)的不一致品的處理程序。6.1、Definition定義Nonconformity is any condition which does not comply with the requirements of the Drawings, Technical Specifications, Code and this Manual. Nonconformities must be properly disposed before the item can be considered to comply with the Code, all nonconformities shall be

4、correctly disposed.“不一致品”是指不符合圖紙、技術(shù)條件、規(guī)范和本手冊要求的情況。在產(chǎn)品建造全過程，當(dāng)被認(rèn)為符合規(guī)范前，所有不一致品必須被正確處理。6.2、Evaluation and Identification鑒定與識別6.2.1 Any person who finds out a suspected nonconformity shall inform the Material Engineer (or the Inspection Engineer when the suspected nonconformity is found during fabricatio

5、n) if the suspected nonconformity is found during receiving inspection.任何人發(fā)現(xiàn)上述6.1中所述情況，若是在材料驗(yàn)收過程中發(fā)現(xiàn)的不一致，應(yīng)通知材料工程師；若是在制造過程中發(fā)現(xiàn)的不一致，應(yīng)通知檢驗(yàn)工程師。6.2.2 The suspected nonconformity shall be evaluated by the Material Engineer or the Inspection Engineer. Once verified as nonconformity, the nonconforming item sh

6、all be attached with the “Hold Label” (JSSN Form A6-01) by the Inspector or Material Inspector. The Inspector or Material Inspector shall prepare the NCR (JSSN Form A6-02).材料工程師或檢驗(yàn)工程師須對不一致品進(jìn)行核實(shí)。一旦認(rèn)為是不一致，立即通知檢驗(yàn)員或材料檢驗(yàn)員將“不一致品扣留標(biāo)簽”（樣表A6-01）貼在不一致品上，并填寫NCR（不一致品報(bào)告）（樣表A6-02）。6.2.3 The “Hold Label” shall be

7、indicated with the Job No., NCR No. and date. If practicable, the nonconforming item shall be moved to a segregated “Hold Area”. The NCR No. is then indicated on the “Process Check List”.“不一致品扣留標(biāo)簽”上要注明產(chǎn)品編號、NCR號和日期。如果可行的話，將不一致品移到隔離的“扣留”區(qū)，然后在“工序檢驗(yàn)表”上注明NCR編號。6.3、Determination處置流程The Material Engineer o

8、r Inspection Engineer shall investigate the nonconforming items and forward the NCR to the Design Engineer, Process Engineer or Welding Engineer, as applicable for the proposed disposition. The proposed disposition of the nonconformity shall be reviewed by the Technology Dept. Manager and approved b

9、y the Chief Engineer. 材料工程師或檢驗(yàn)工程師應(yīng)對不一致品進(jìn)行調(diào)查，而后將NCR提交給設(shè)計(jì)工程師、工藝工程師或焊接工程師提出處置方案。最終處置方案應(yīng)由技術(shù)部長審核總工程師批準(zhǔn)。The NCR shall be presented to AI for acceptance and for his designation of additional inspection points, where applicable.NCR應(yīng)提交給AI認(rèn)可，并在適用時(shí)指定額外的檢測點(diǎn)。The disposition result of the nonconformity shall be v

10、erified by the Material Engineer or Inspection Engineer, reviewed by the Quality Inspection Dept. Manager, approved by the QA Engineer and verified by AI.不一致品的最終處置需由材料工程師或檢查工程師核對，由質(zhì)檢部部長審核，由質(zhì)保工程師批準(zhǔn)并由AI確認(rèn)。6.4、Disposition處置方法The dispositions of nonconformities are classified into the following cases, s

11、uch as “Reject”, “Use As Is”, “Repair” or “Others”.對不一致品的處置分為幾種情況：“報(bào)廢”、“回用” 、“返修”和“其他”。 6.4.1 “Reject” Disposition“報(bào)廢”處理a) When the nonconforming item is rejected, the Material Engineer or Inspection Engineer shall distribute the copies of NCR to the Workshop Manager, Warehouse Keeper and other rela

12、ted departments to inform them of the rejection.當(dāng)不一致品作為“報(bào)廢/退貨”處理時(shí)，材料工程師或檢驗(yàn)工程師應(yīng)負(fù)責(zé)將NCR的復(fù)印件分發(fā)給車間/倉庫等相關(guān)部門，通知他們報(bào)廢情況。b) The Material Inspector has responsibility to note “Return to vendor” on the “Material Receiving Inspection Record” rejected to the rejected material. The Inspector has responsibility to

13、note “Reject” on the “Process Check List” and reports/ records related to the reject item up to this stage. The Material Inspector or Inspector shall replace the “Hold Label” with the “Reject Label” (JSSN Form A6-03) which shall indicate the disposition, either “Scrap” or Return to vendor”.材料檢驗(yàn)員應(yīng)負(fù)責(zé)在

14、有關(guān)報(bào)廢材料的“材料驗(yàn)收記錄”上注明“退貨”字樣；檢驗(yàn)員應(yīng)在直到此階段為止的有關(guān)此報(bào)廢品的“工序檢驗(yàn)表”、報(bào)告/記錄上注明“報(bào)廢”字樣。材料檢驗(yàn)員或檢驗(yàn)員還須將“不一致品扣留標(biāo)簽”換成“報(bào)廢/退貨”標(biāo)簽（樣表A6-03）。c) The Production Dept. Manager has the responsibility to remove the rejected materials, parts or items from the work area to the “Reject Area”.生產(chǎn)部部長有責(zé)任將報(bào)廢材料、部件或產(chǎn)品從工作區(qū)域移至“報(bào)廢區(qū)”。6.4.2 “Use As

15、 Is” Disposition“回用”處理a) “Use As Is” disposition of nonconformity along with the technical justification shall be proposed by the Design Engineer, Process Engineer or Welding Engineer as applicable. AIs prior concurrence shall be obtained.不一致品的“回用”處理意見以及技術(shù)評估須按專業(yè)要求由相應(yīng)的設(shè)計(jì)工程師、工藝工程師和焊接工程師提出，并須事先征得AI的同意。

16、b) Any required revisions of drawings, calculations，design report and procurement documents are made as described in Section 3 & 4 of this Manual, including submittal to the AI for his review and acceptance.涉及到圖紙、計(jì)算書和采購文件的更改，按本手冊第3和4章所述進(jìn)行質(zhì)量控制，包括提交給AI供其審核和認(rèn)可。c) The Inspector or Material Inspector

17、 shall replace the Hold Label with “Use As Is” Label (JSSN Form A6-04) and the Workshop shall be permitted to proceed with the subsequent work.檢驗(yàn)員或材料檢驗(yàn)員應(yīng)將“不一致品扣留標(biāo)簽”換成“回用標(biāo)簽”（樣表A6-04），并允許車間進(jìn)行下一步工序。6.4.3 “Repair” Disposition“返修”處理a) If corrective action to the nonconformity involves repair, the Process

18、 Engineer shall organize to prepare the related repair procedure, “Process Check List” and NDE instruction etc. as appropriate. Regular weld repairs which can be conducted according to an approved procedure accepted by the AI by using existing Qualified WPS and examined by original NDE method are no

19、t considered as nonconforming and are not reported as nonconformity on NCR.如果需對不一致品進(jìn)行返修，工藝工程師應(yīng)組織編制相關(guān)的返修程序、“工序檢驗(yàn)表”和無損檢測要求等。對于常規(guī)的焊縫返修，即按AI已認(rèn)可的程序，采用現(xiàn)有已評定的WPS，并用原無損探傷方法檢查，可不作為不一致品，也不必出NCR。b) Repair disposition of nonconformities shall be reviewed by the AI for designation of the additional inspection po

20、ints on NCR or Process Check List.不一致品的返修方案須經(jīng)AI審核并在NCR或工序檢驗(yàn)表上標(biāo)上追加的檢驗(yàn)點(diǎn)。c) When the Process Engineer or Welding Engineer and Inspection Engineer have obtained the Technology Dept. Managers approval and AIs concurrence of final disposition, they shall instruct and supervise the workshop to perform repa

21、ir work related to the Nonconforming Item.工藝工程師或焊接工程師和檢驗(yàn)工程師在最終處理方案已獲得技術(shù)部長批準(zhǔn)和AI認(rèn)可后，應(yīng)指導(dǎo)并監(jiān)督車間進(jìn)行不一致品的返修。d) Defects in material may be repaired provided acceptance by the AI is first obtained for the method and extent of repair. Defective materials that can not be satisfactorily repaired shall be rejecte

22、d. For detail see “Procedure for Repair of Defects in Weld or Material” JSSN/CX06.對于材料的缺陷，只要其返修方法和范圍事先得到AI的認(rèn)可，就可以進(jìn)行返修。無法取得滿意的返修效果的缺陷材料應(yīng)判為“報(bào)廢”。詳見程序文件焊接或母材缺陷返修程序JSSN/CX06。e) The repair results shall be re-examined and recorded by the Inspector and reviewed by Inspection Engineer according to the repai

23、r or relevant procedure. Only with the acceptance of repair by the Inspection Engineer can the Inspector remove the Hold Label and the subsequent process proceeds. The NCR and other necessary documents shall be presented to the AI for his verification.對于返修完的部件，須按返修及有關(guān)程序，由檢驗(yàn)員重新檢驗(yàn)并記錄，檢驗(yàn)工程師應(yīng)再次核查返修結(jié)果。只有當(dāng)檢驗(yàn)工程師認(rèn)定返修合格后，檢驗(yàn)員方可去除“不一致品扣留標(biāo)簽”進(jìn)入下一步工序。NCR和其它相關(guān)文件應(yīng)提交AI審核。6.4.4 “Others” Disposition “其他”處理T