Contract Quality Requirements Manual SLM Issue 3

Transcription

1 Contract Quality Requirements Manual SLM Issue 3 20 th October 2015 Gary Rushforth Supply Chain Quality Sellafield Ltd

2 Introduction Sellafield Ltd (SL) aims to deliver excellence in everything it does, operating safely, securely, reliably and predictably. This expectation extends to the SL Supply Chain in terms of delivering products / services safely, to schedule, of the right quality and to agreed cost. The aim of this presentation is to communicate the requirements to ensure SL s Supply Chain delivers our products and services as described above

3 SLM is one of a series of documents within SL Management System. It defines the Contract Quality Requirements that will enable delivery of products and services to the appropriate Quality Grade Presented in booklet form Above BS EN ISO 9001:2008 Nuclear Safety Culture Graded approach Flow down of requirements Resource Management Subcontractor Control Assurance Deviation of non conforming product Quality Plan LTR s

4 Commitment to Working Together SL are committed to working together with its suppliers in delivering excellence in everything it does through; the right people, right skills at the right time. This is achieved through; Open and Honest Communication Throughout the supply chain at all levels and tiers. Checking understanding of specifications at all levels and tiers Sharing Learning LFE Focussed improvements Right measures with actions Structured Problem Solving Decisions taken based on facts, root cause identification and robust corrective actions.

5 1 Nuclear Safety - definition The protection of workers, the public and the environment from undue radiological hazard by achievement of proper operating conditions, prevention from accidents and the mitigation of accident consequences

6 1 Nuclear Safety - definition The protection of workers, the public and the environment from undue radiological hazard by achievement of proper operating conditions, prevention from accidents and the mitigation of accident consequences All personnel involved in design, fabrication, installation, inspection and testing understand how their role impacts upon nuclear safety and how the failure of a product or service can impact upon the associated plant and local community.

7 2 - QMS Requirements Contractors / Suppliers shall operate a UKAS certified Quality Management System in accordance with BS EN ISO The requirements of the CQR Manual are to be flowed down to all tiers of the supply chain where the risk associated with the procurement of goods or services continues to be either a Quality Grade 01,02 or 03 Contractors shall have a Business Continuity Plan in place Contractors shall have a documented procedure for LFE which clearly demonstrates improvements and effective implementation.

8 3 - Resource Management incl. SQEP Those undertaking work are Suitably Qualified and Experienced with a clear auditable trail that demonstrates that the contractors employees are as equally SQEP d as the customers employees are for the same or similar role Implement and maintain a competency/training register which includes: All personnel Role Profile Status of Training Experience in the Role Training Plan Training and Qualification Records Annual Reviews

9 4 Procurement A Graded Approach SL deploys a graded approach to the procurement of all goods and services which ensures that we focus resource and effort on those activities that pose greatest risk/hazard The Quality Grade determines the level of control that will be applied. The higher the level of risk, the greater the level of assurance to mitigate the associated risk. SLP : How do I determine the Quality Grade of My Supply Chain Requirements

10 Graded Approach The Way Forward Specify need Risk assessment Quality grade SAP code Controls Radiological / Nuclear Conventional Safety Environmental Business Risk Risk Quality Grade Very High QG 01 High QG 02 Medium QG 03 Low / No risk QG 04 SLM Contract Quality Requirements Manual Supplier Selection QASL Inspection Requirements Off Site and Receipt Inspection

11 4 Procurement A Graded Approach Quality Grade 01 Very High Risk & Quality Grade 02 High Risk Both grades require SL oversight controlled by Quality Plans, Inspection and Test Plans or Method Statements to document the quality requirements. Quality Grade 02P Proprietary This grade is utilised for proprietary spares and equipment i.e. typically catalogue items. The contractor shall apply Quality Grade - 03 requirements. Quality Grade 03 Medium Risk This grade requires SL inspectors to conduct receipt inspections. A Quality Plan may be required by exception. Quality Grade 04 Low/No Risk Excluded from the CQR requirements. Quality Grade 04 should only be used for items that if fail have low or no impact with regards to safety and risk.

12 Quality Assessed Supplier List Goods and Services defined as having a Quality Grade of 01, 02 or 03, shall only be procured from Suppliers that have been through a process of evaluation and are listed on the Quality Assessed Supplier List (QASL). Evaluation shall either by the Complete Tender Management (CTM) tender process or by QASL Questionnaire (SLF ) NOT a list of preferred suppliers NOT a barrier to a company wanting to supply to SL Produced and maintained by Supply Chain Quality

13 5 Quality Plans A top level Quality Plan is required covering the entire scope of work and should be a live document subject to continual review by the Contractor. Any significant changes should be subject to SL approval. Individual Inspection and Test Plans should be generated for each work package so the work can be signed off when a work package is complete. The contractor shall not commence work identified in the Quality Plan and / or Inspection and Test Plan prior to SL approval. Any special processes identified within the Quality Plan and/or Inspection and Test Plan shall have an appropriate procedure which will require SL acceptance. All hold points must be complied with, failure to comply will result in SL raising a non-conformance report.

14 6 Sub-Contractor Control The Contractor shall ensure that the full extent of their supply chain has a clear understanding of the Sellafield Ltd contract Technical and Quality specified requirements. If the Contractor subcontracts work, the Contractor is responsible for controlling the scope of work in accordance with the associated Quality grade and the specified requirements The Contractor shall implement a process for ongoing verification and monitoring of their Subcontractors to ensure that they are delivering products and services safely, to schedule, to the specified requirements and to the agreed cost.

15 7 - Assurance SL reserve the right to undertake assurance activities within the supply chain. Contractors / Suppliers shall ensure that Sub-Contractors are informed of this requirement. Contractors shall develop and implement a risk based audit programme which covers the scope of work. The Contractor on request shall report any findings to SL from the audit programme. The Contractor shall notify SL of any Management Review actions which will effect compliance with contractual requirements. Contractors shall establish metrics which include safety, schedule, quality and cost performance. Contractors shall report the agreed metrics at each financial period end. These requirements shall be cascaded down the supply chain.

16 8 Deviation and Non-Conformance Standard requirements for managing deviations and Non-Conformance in accordance with ISO The Contractor shall establish a documented process to identify a request for deviations or a justification for the use of non-conforming product from SL specified requirements Aligned with; SLP How Do I resolve engineering queries SLP How Do I Monitor and Report Non Conformances SLF Defect /Non conformance Report Contractor and subcontractors shall not repair spoilt work after final inspection by the nominated Inspectorate without prior written approval from SL

17 11 Production and Service Provision Material test Certificates (Stainless and Carbon Steels) must be; The original material test certificate, or a legible red line stamped version stating verified true certified copy of the original by the mill/stockist. Certification must be as specified in BS EN type 3.1 which includes chemical and mechanical data. Where a product such as a pipe flange has been manufactured, the Contractor must provide both the original material test certificate for the base material and the certificate provided by the flange manufacturer. Contractors must endorse all material test certificates to verify conformance with requirements. This verification must be carried out by a suitably qualified and experience authorised personnel.

18 Potential for Counterfeit Materials Potential for suspect/counterfeit materials in Global supply chains Global markets, value for money opportunities, some associated risks Vendors with little / no experience in the nuclear industry entering market Long supply chains Counterfeit valves/circuit breakers identified in US nuclear facilities Appropriate response required

19 Examples

20 11 Production and Service Provision Release of goods shall either be by; SLF (5199) Intermediate Certificate of Inspection. This shall be used when goods are being released between the Contractor / Contractor and Sub-Contractor / Contractor. SLF (5059) Final Certificate of Inspection. This shall be used when goods are being released and despatched direct to SL.

21 13 Records SLP Life-Time Records (LTR no Q) Correction Fluid (Tippex) is not to be used. Mistakes should be crossed out by a single line so the previous information can still be read, signed, stamped and dated at the side of the change. The person who conducted the activity being signed for is the only person authorised to sign a document. Documents are not to be signed as pp on behalf of another person. Drawings included in the LTR must be SL stamped approved versions. Records are to be generated and available for verification concurrently with the activity they relate. Records which require a signature MUST be signed this includes the customers signatures as there is a responsibility for ensuring they also comply!!!!!

22 Thank You!