Add N / A to this field. 5 Rolls-Royce order number 6 Process number 7 All other boxes above 1. Define Problem 8 Define the problem.

Transcription

1 SABRe: Deviation permit / concession PIR Checklist.. Below is a checklist that should be referenced when completing a level 1 Problem Improvement Request (PIR) form in support of a deviation permit / concession submission for declared Non-Conformance (Refer to SABRe Control of nonconforming product). Attached at the end of the checklist is an example of a Level 1 PIR form, with information guidelines for deviation permit / concession related PIR's. The supplier is responsible to ensure the correct form is used. TABLE 1 Item Reference. Requirement Check 1 Correct form Supplier to check that the correct, up-to-date form is being used to complete the level 1 PIR. PIR number This number must reference the supplier s application number in box 1.3 of the deviation permit / concession application. In the case of multiple PIR s on a single deviation permit / concession application, each PIR must have a unique number. 3 Related Add N / A to this field. notification number 4 Reference number Add N / A to this field. 5 Rolls-Royce order number 6 Process number 7 All other boxes above 1. Define Problem 8 Define the problem. 9 Contain the problem 10 Name, Position, sign and date The Rolls-Royce purchase order number is to be applied to the PIR. The operation where the non-conformance was produced. All remaining boxes above 1. Define Problem, are self-explanatory and need to contain entries from the supplier. The supplier is to define the non-conformance. This should describe in words the contents of box 3.1 on the deviation permit / concession. The description must be free standing, brief, concise, and contain no root cause. 48 hour check sheet complete within 48 hours - Insert N / A Temporary fix to protect customer - Information included must be in line with the appended guidelines. The person confirming containment actions have been implemented must complete these boxes.

2 11 Find the Root Cause of Escape Enter N / A - No escape has occurred 1 Prevent Further Escapes 13 Find Root Cause of Problem 14 Implement corrective action Enter N / A - No escape has occurred This section must clearly state the root cause of problem. Information included must be in line with the appended guidelines. This section must clearly state that all root causes identified above (13), have been addressed and prevented from re-occurring. It must also contain a statement of all read across actions taken as part of the investigation. Information included must be in line with the appended guidelines. 15 Verify Fix This section must list all activities taken to verify that the corrective actions identified above (1 & 14) have eliminated the root cause(s) of the problem and of the escape. Information included must be in line with the appended guidelines. 16 Level 1 Completion These boxes must be completed by the person submitting the completed PIR to Rolls-Royce. 17 Liability Accepted This section must clearly show if the supplier accepts or rejects liability for the non-conformance.

3 PIR Coordinator: A.N. Other Tel: Fax: s.com Part No. BIT 1345 Process No. 1. Define problem Clearly define problem 6 Vendor Code or RR Plant Code / Dept: 5431 Vendor or RR Plant / Dept name: Aeroparts Ltd. Contact name: F. Bloggs Tel: Fax: F.Bloggs@Aeroparts.com Vendor Part No. If Applicable Description: : Widget Serial / Batch No Related notification No s. N / A Reference No. N / A Date PIR issued to RR: RR Order No Quantity: Does the problem definition include how the issue was found? Does the problem definition include what has been seen? Does the problem definition include which spec has been deviated against (quote drawing grid reference / specification etc.)? Is there any history of this problem, including similar parts? What is the quantity impacted / serial numbers etc? Contain Problem Containment check sheet complete within 48hrs N/A Detail temporary fix to protect customer 9 Have all parts post Inspection been checked? Does this problem affect parts that have already been despatched? Have all affected parts been suitably quarantined? What inspection method detected the error? How is the supplier going to temporarily check for the non-conformance? How is the supplier going to prevent its release prior to receipt of approved deviation permit / concession from Rolls-Royce.? Have all appropriate personnel been informed of non-conformance? Name: F. Bloggs Position: Quality Engineer Sign: N / A Date:

4 1 3. Find root cause of escape (Why has your quality / inspection process failed?) Support with evidence of appropriate process compliance checks & root cause analysis (use 5 whys, fishbone, flowchart, etc. as appropriate) N / A - No escape has occurred Note - Operator / human error not acceptable 4. Prevent further escapes (list actions taken to fix root cause of escape) Supporting evidence required N / A - No escape has occurred 5. Find root cause of problem Support with evidence of appropriate process compliance checks & root cause analysis (use 5 whys, fishbone, flowchart, etc. as appropriate) Is there evidence (copies or photographs) that root cause analysis tools have been used? 13 Have suitable tools been used for the type of problem being investigated? Tools used could include: o Process flow charts / process surveillance (to understand the process) and where more than one cause might apply o 5 why s o Fishbone diagrams (to identify causes / potential causes where more than one may apply) Have existing processes been followed? Is there a clear identification of the root cause(s) that have been identified? ~ Try and ask a further WHY against the proposed root cause, if you can, then you have not drilled down far enough. Add Root cause statement If operator / human error is identified, the root cause of this human error must be clearly demonstrated as part of the root cause analysis 11 1 Note - Operator / human error not acceptable

5 6. Implement corrective action (list actions taken to permanently fix problem) Supporting evidence required Have all the root causes identified in Section 5 had actions taken to fix the causes of the problem? Where a root cause of problem has not been addressed directly but eliminated by mistake proofing (for example replacing operator re-training with new mistake proof tooling) this must be clearly stated and justified. The risk area subject to mistake proofing must bee highlighted in section 5. Examples of activities could be: o Use of mistake proofed fixtures ~ including evidence that tooling numbers are called up on routings & photos exist to show how the new fixtures are used o Updates to inspection instructions o Updates to documents / work instructions o Updates to other procedures o Evidence that all inspectors / operators etc. have knowledge in the use of the new instructions / fixtures Has evidence of the actions taken been submitted? e.g. o Photo s of before / after o Copies of before / after instructions etc. o Training procedures, who has been trained & what is the on-going training programme Have actions in this section been READ ACROSS to other similar parts & processes ~ evidence is required of this with the relevant part details or a statement if not applicable 7. Verify Fix (list actions taken to confirm effectiveness) Supporting evidence required Has evidence been submitted to show that you have checked the corrective actions taken in 6 and can confirm they are effective and will prevent further re-occurrences? Evidence could include: On-going SPC data to show process is in control Quantity of conforming product Internal audit results 15 14

6 Inspection results Proving by experiment that the incorrect parts can no longer be made. Has a visit from a Rolls-Royce Supplier Quality representative been conducted to check that the actions have been completed as declared? Completed batch card after corrective actions have been put in place If any long terms corrective actions have been identified, evidence of an improvement plan will be required PLEASE ENSURE THAT YOU HAVE ANSWERED YES TO ALL THE QUESTIONS BEFORE SENDING YOUR SUBMISSION. ANY ANOMOLIES NEED TO BE DISCUSSED WITH THE PSQE Level One completion 16 Vendor or RR plant / Dept Liability accepted? YES / NO 17 Name: F Bloggs Position: Quality Engineer Sign: N / A Date: