Page 1of 25 U.T.D. Unipart Rail Technical Dossier O Rings IMPLEMENTATION DATE: STATUS: LIVE AUTHOR: MICHAEL K HUBBARD APPROVED BY: A. THURLBOURN AUTHORISED BY: R. CHAPPELL DOCUMENT OWNER: BRITISH SEALS AND RUBBER MOULDINGS LIMITED ISSUED BY: Michael K Hubbard British Seals and Rubber Mouldings Limited 7 Brundon Lane Sudbury Suffolk CO10 1XR Tel: 01277 815300 Fax: 01277 815350
Page 2of 25 U.T.D. Introduction The is the U.T.D. nominated representative for the British Gaskets Group Limited. The product supplied is used in numerous applications, which are not known, and the specific vehicle type cannot be identified. The drawings and specification sheets determine the capability of the product.
Page 3of 25 ACOP/EOC1003 Supplier Accreditation supporting documentation To satisfy the requirements of the Duty Holders, the supply chain has the responsibility to provide evidence of compliance to the ATOC Code of Practice EC/01003. Unipart Rail has established a validation model, which demonstrates to the Duty Holder that the minimum requirements have been met. This package is identified as the Supply Accreditation Pack (SAP). To gain the Duty Holder s acceptance the following is a minimum requirement to demonstrate compliance to the Code of Practice 1. Contents of section 1, 2, 3 & 11 2. 3 tier controls supporting GM/RT2450 see section13 3. Mitigation of risk within supply chain see section 11 List of Appendices Appendix A Appendix B Appendix C 3 Tier Support Control of Risk Concession Application
Page 4of 25 REVISION RECORD Revision Date of Page Numbers Reason for Revision Number Revision Issue 2 19.11.03 All References to ISO9001:2000 & Update of Part Numbers Issue 3 22.07.04 All Update of Part Numbers Issue 4 08.02.04 All References to ISO/TS 16949:2002 & Update Of Part Numbers Issue 5 September 2006 All Update Part Number & Re-Issue to UTD Ver 2 Issue 6 May 07 All Change of name from Railpart RTD to Unipart UTD & Safety Critical Products Issue 7 September 2011 All Complete Review Issue 8 June All Complete Review & Update
Page 5of 25 Section 1 Pt. No. and General Description Included in attached list. Location: Filing cabinet in Production Hall. Section 7 Quality Plan R.T.D. 000225 Folder Control Plan UTD No. 000225 O Rings June Section 2 Engineering Drawings Inspection Office at B.S.R.M. Inspection Area at B.G. Production Hall R.T.D. 000225 Folder Computer file "Sect.2 Part Master List" Control of Eng. Drgs. - Business Process 4.05 Section 8 External certificates BS EN ISO 9001:2008 Link Up I.D. 6694 ISO/TS 16949:2009 / Commercial Manager Section 3 Workshops Standards and Instructions R.T.D. 000225 Folder ISO 9001:2008 Quality Management System Business Policy Manual & Processes. / Production Manager Section 4 Engineering Change Control R.T.D. 000225 Folder ISO 9001:2008 Quality Management System sections ISO/TS 16949 Business Processes 4.05 Control of Customer Drawings Section 9 Quality Assurance Procedures R.T.D. 000225 Folder Quality Manual Section 10 Hazard Log Rejections C.A.R.s C.A.R. folder at B.S.R.M. Section 11 Risk Assessment Assessment Records F.M.E.A.s if requested (None requested to date). Section 5 Design and Performance Not Applicable to B.S.R.M. Section 12 Training and Competence Training Matrices Warehouse and Office folders at B.S.R.M. Section 13 Selection and Control of Supply Chain Section 6 Health & Safety R.T.D 000225 Folder Material Safety Data Sheets Approved Supplier List ISO /TS 16949 Business Process 7.04 Evaluation of Vendors.
Page 6of 25 WORKING DOCUMENTS The following working documents are referred to within this UTD. Ensure that the latest issue of each document is obtained and worked to. Specification / Drawing No Description Location UTD Section No. See Attached See Attached QA Procedures See Section 9
Page 7of 25 REFERENCE SPECIFICATIONS: The following reference documents / certificates are referred to within this UTD: Specification No Description Location UTD Section No. Certificate number Q 05299 Link Up I.D. 6694 Certificate Number : TS 513676 ISO 9001:2008Certifi cation Link Up Registration ISO/TS 16949:2009 See section 8 See section 8 See Section 8
Page 8of 25 Part Number and General Description Section 1 Designated Person: Generic Group: O Rings Cat No Description Part No. Type No. Various See Page 10
Page 9of 25 Part Number and General Description Section 1 Item Description : See Catalogue Number advised as Safety Critical BR Cat No. 010/052125 Internal Part No: 9024495/06 OEM Part No: 4522 General Description/Specifications: Nitrile O ring Quality Assurance Rating: 4 Consumable/Repairable: Consumable. Vehicle Fitted to: O Rings may be fitted to various vehicles in numerous applications. Applications not specified. Sub-Component of: Not specified by Unipart Rail Class: Not specified by Unipart Rail Performance / Capability Details: As per Material Specifications sheets. (However actual applications not specified). Service Life: Service life of the product is determined by service interval of the part to which it is fitted.
Page 10of 25 Cat No. Description Drawing reference Safety Critical BSRM Ref. Material description QA Special (Nitrile 50) 4 010/052050 O Ring M-A3-9024493/11 Y 2894 010/052100 O Ring M-A3-9024494/21 Y 2523 Nitrile 4 010/052125 O Ring M-A3-9024495/06 Y 4522 Nitrile 4 010/052334 O Ring M-A3-9024500/15 Y 3508 Nitrile 4 010/052456 O Ring M-A3-9024503/17 Y 3725 Nitrile 4 010/052465 O Ring M-A3-9024503/26 Y 4089 Nitrile 4 010/052520 O Ring M-A3-9024505/01 Y 2551 Nitrile 4 015/073003 O Ring 2027684470 Y 4336 Nitrile 4
Page 11of 25 Engineering Drawings Section 2 Designated Person: Cross Reference: For O Rings supplied by British Seals and Rubber Mouldings Ltd refer to list in Page 10 of this document. Drawing Distribution Control System: Business Process 4.05 Control of Customer Drawings. Location of Engineering Drawings: Engineering Drawings for the above are held in files in the Main Office.
Page 12of 25 Workshop Standards and Instructions Section 3 WORKSHOP STANDARDS / INSTRUCTIONS: Designated Person: Cross Reference: British Seals and Rubber Mouldings Ltd. use the Unipart Rail catalogue numbers (typically nnn/nnnnnn) as a unique part number to identify any given part within its internal systems (eg Quality / Production / Accounts). Location of Master Workshop Standards and Procedures: Engineering Drawings - Main Office Quality Manual and Procedures in s Office. Document Distribution Control System: Business Policy Manual. Processes: - 4.01 Business Management System Documentation. 4.02 Internal Document Control. 4.03 Control of Customer Specifications. 4.04 Control of National / International Standards. 4.05 Control Of Customer Drawings. 4.06 Control of Regulatory Requirements. 4.07 Control of Records. 4.08 Engineering System Change Request. 5.01 Management Commitment.
Page 13of 25 5.02 Management Review. 6.01 Induction. 6.02 Employee Development. 7.01 Product Realization. 7.02 Customer Enquiries. 7.03 Contract Review. 7.04 Evaluation of Vendors. 7.05 Purchase Orders. 7.06 Incoming Material Verification. 7.07 Product Manufacture. 7.08 Despatch. 7.09 Tooling Management. 7.10 Planned Maintenance. 7.11 Calibration. 8.01 Customer Satisfaction. 8.02 Internal System Audits. 8.03 Statistical Process Control. 8.04 Non Conformance Control. 8.05 Corrective Action. 8.06 Preventive Action. 8.07 Continual Improvement.
R.T.D. ISSUE: 8 REVISION: A PAGE: 14 OF 25 Engineering Change Control Section 4 Designated Person: Concession and Variations: British Seals and Rubber Mouldings Limited supply O Rings to The requirements specified on Engineering Drawings or, when drawings not available, to a sample (and the material to be used agreed / accepted / approved by Unipart Rail). There have not been any requests from Unipart Rail to vary from the above, should there be any variations they will be covered as detailed in Business Policy Manual and Business Process 7.03 Contract Review. British Seals and Rubber Mouldings Limited have not applied for any Concessions from Unipart Rail. In the event of a Concession being sought British Seals & Rubber Mouldings will submit Concession form [Appendix C] (typically for dimensions / thickness), Business Policy Manual & Business Processes 7.03 Contract Review & 8.04 Non Conformance Control give details of actions to be taken. Location of Register of Variations and Concessions: Business Policy Manual and Processes s Office. Concessions and Corrective Action Reports (C.A.R.s) Product Inspection Centre
R.T.D. ISSUE: 8 REVISION: A PAGE: 15 OF 25 Design and Performance Requirements Section 5 Designated Person: Cross Reference: The information detailed below refers to all parts currently being supplied by British Seals and Rubber Mouldings Limited. Design and Performance Requirements: The Design of components supplied by British Seals and Rubber Mouldings Limited was carried out by the Original Equipment Manufacturer. All parts produced are to Railway Drawing specifications / Standards as supplied by Unipart Rail UK Ltd. Although the OEM sets the Design Performance Requirements, B.S.R.M. use data analysis techniques to ensure any recurring Performance flaws are reviewed to ensure continual improvement of the product. Typical data information used for analysis is warranty / rejection trends and variations / concessions. If B.S.R.M. / Unipart Rail wish to make any design or performance changes then a third party would have to be consulted to ensure correct approvals are met before any major changes are made. Location of Design and Performance Procedure. N/A
R.T.D. ISSUE: 8 REVISION: A PAGE: 16 OF 25 Health and Safety Section 6 Designated Person Health and Safety Business Process 7.07 Product Manufacture gives details for Handling, Storage, Packaging, Preservation and Delivery of goods supplied by British Seals and Rubber Mouldings Limited. If supplier changes a specification or identifies that they cannot supply to that specification, it will initiate a request for a revised Material Safety Data Sheet if applicable. No hazardous materials or components or packaging supplied. Material Safety Data Sheets are available on request. Location of Health and Safety Information: Business Policy Manual s Office.
R.T.D. ISSUE: 8 REVISION: A PAGE: 17 OF 25 Quality Plan Section 7 Designated Person: Product Type: Individual or Generic Group O Rings. Quality Plan Information: The company Mission Statement and Quality Policy (see Business Policy Manual section 3) states the company aim to establish itself as a major and dominant supplier through its commitment to satisfying customers needs (economic, quality, reliability, safety and environment). The Business Policy Manual and Processes give details of the procedures to be followed from receipt of an order to despatch to the customer. Internal Quality Audits are carried out in the quality system on monthly basis to ensure continuing compliance with BS ISO 9001:2008 & ISO/TS 16949:2009 Location of Quality Plan:
R.T.D. ISSUE: 8 REVISION: A PAGE: 18 OF 25 External Certification Section 8 Designated Person: Certification Requirements Suppliers who are not the OEM, and have been supplying spares into Unipart Rail since pre privatisation can refer to Grandfather Rights, as the product is tried and tested on Vehicles which belonged to the old British Railway network External Certificate Information: Approval: See ISO 9001:2008 Certificate on Page 7 of this document. See Link Up certificates on Page 7 of this document. See ISO/TS 16949:2009 Certificate on Page 7 of this document. Location of External information or register: N/A
R.T.D. ISSUE: 8 REVISION: A PAGE: 19 OF 25 Quality Assurance Procedures Section 9 Designated Person: Quality Assurance procedures: Business Policy Manual Processes: - 4.01 Business Management System Documentation. 4.02 Internal Document Control. 4.03 Control of Customer Specifications. 4.04 Control of National / International Standards. 4.05 Control Of Customer Drawings. 4.06 Control of Regulatory Requirements. 4.07 Control of Records. 4.08 Engineering System Change Request. 5.01 Management Commitment. 5.02 Management Review. 6.01 Induction. 6.02 Employee Development. 7.01 Product Realization. 7.02 Customer Enquiries. 7.03 Contract Review. 7.04 Evaluation of Vendors. 7.05 Purchase Orders. 7.06 Incoming Material Verification. 7.07 Product Manufacture. 7.08 Despatch. 7.09 Tooling Management. 7.10 Planned Maintenance. 7.11 Calibration. 8.01 Customer Satisfaction. 8.02 Internal System Audits. 8.03 Statistical Process Control. 8.04 Non conformance Control. 8.05 Corrective Action. 8.06 Preventive Action. 8.07 Continual Improvement. Quality Assurance Manual s Office
R.T.D. ISSUE: 8 REVISION: A PAGE: 20 OF 25 Hazard Log Section 10 Designated Person: Hazard Log: It should be noted that British Seals and Rubber Mouldings Limited supply O rings to Unipart Rail in materials specified by Unipart Rail (in Engineering Drawings). However, this does not alleviate British Seals and Rubber Mouldings Limited from observing and reporting any faults or weaknesses that may arise or be found from Rejection analysis. Customer Complaints and Rejections (including Train Operator Risk Assessment Reports and National Incident Reports) are recorded by the Quality Assurance Department and analysed on a regular basis for any trends or significant occurrences and any potential or realised hazards identified. Hazard Log Location: Customer Complaints, Rejections and analysis results held in Product Inspection Centre.
R.T.D. ISSUE: 8 REVISION: A PAGE: 21 OF 25 Risk Assessment Records Section 11 Designated Person: Risk Assessment Records: Risk Assessment will be carried out when specified by customer (Customer Specific). As yet no requests have been received from Unipart Rail. When requested, Risk Assessments will be carried out with the help of Unipart Rail personnel using the Risk Assessment pro-forma currently in use at Unipart Rail. Risk Assessment Records; Risk assessment records for all components will be held in this Document. Location of Risk Assessment Records: N/A
R.T.D. ISSUE: 8 REVISION: A PAGE: 22 OF 25 Risk Assessment O Rings To contain a substance within a dynamic system. Typical Conditions Typical Substances Possible Failure Possible Consequences Risk Assessment Risk Rating (under any conditions (from any failure) with any substance). Could range from partial to full failure. Low Pressure Liquids Leak Slipping Likelihood Possible (2) High Temperature Oil Severity Slight (2) 4 Antifreeze (corrosive) High Pressure Gas Failure of seal Burning / Scolding Likelihood Possible (2) High Temperature Exhaust gas Severity Moderate (3) 6 Steam High Pressure Flammable liquid Pin Hole Leak Inhalation of fumes Likelihood Possible (2) Low Temperature (fire source risk) Severity Moderate (3) 6 Fuel Low Pressure Pin Hole Leak Likelihood Possible (2) Low Temperature Severity High (4) 8 Control Measures - Manufactured to specification. - Control of suppliers - Control of first-off and mid-point inspection levels - Packaging to prevent damaging in transit - System control of part order to prevent wrong component being supplied (including administration). If used in door system Likelihood Possible (2) - door opening Severity High (4) 8 (worst case)
R.T.D. ISSUE: 8 REVISION: A PAGE: 23 OF 25 PRIMARY CONTROLS To support GM/RT 2450 ISO 9000 Quality System Supplier Pre- Qualification WP11 Purchasing Control Quality Plan SECONDARY CONTROLS To support GM/RT 2450 WP08 Purchasing, WP11 Vendor Appraisal WP15, Document and data control WP01 Order acceptence.wp04, Process controls and standards UTD0225 Product Risk Assessment TERTIARY CONTROLS To support GM/RT 2450 WP08 & WP11 Supplier Performance Receiving Inspection and Test Control of Change to source of Supply Purchasing Procedures & Practices WP08. Evaulation of Suppliers WP11, Drawing and Specification Control WP15 Surveillance at Suppliers WP11 Purchasing Procedures & Practices WP08 Evaluation of Suppliers WP13 Variations and Concessions application Processing of Contracat Variations WP 13 Contract Review WP01 Receipt of Sales Orders Unipart Rail Procedures MM/OP 5004 Safety & Recall Procedure WP13 Control of Non conforming product
R.T.D. ISSUE: 8 REVISION: A PAGE: 24 OF 25 Training and Competence Section 12 Designated Person: Training and Competence Business Process 6.02 Employee Development gives details of identification of training requirements. Records; Training records held in Skills Matrices. Location Records: Matrices held in Warehouse Office folders
R.T.D. ISSUE: 8 REVISION: A PAGE: 25 OF 25 Selection and Control of Supply Chain Section 13 Designated Person: Selection and Control of Supply Chain: Business Process 7.04 gives details of the evaluation of new suppliers, supplier development and supplier performance. Records; Approved Supplier list. Location of Records: Approved Supplier list held by Purchasing Manager