第6章-不一致品的纠正

1、JSSN江苏世能化工设备有限公司QUALITY CONTROL MANUAL质量控制手册DOC.NO.：JSSN/SC-01文件号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规范第I卷、第卷第1册及B31.1在工厂建造与现场安装锅炉压力容器及其部件和压力管道Revision No修订号.：0Correction of Nonconformities不一致品的纠正Section章：6Page：6 of 6 第6页 共6页 6.0、Purpose目的This Section describes the disposition procedure of nonconformities found at receiving inspection and during fabrication of Code Items.本章描述了在材料验收及规范产品的制造过程

3、中发现的不一致品的处理程序。6.1、Definition定义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”是指不符合图纸、技术条件、规范和本手册要求的情况。在产品建造全过程，当被认为符合规范前，所有不一致品必须被正确处理。6.2、Evaluation and Identification鉴定与识别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.任何人发现上述6.1中所述情况，若是在材料验收过程中发现的不一致，应通知材料工程师；若是在制造过程中发现的不一致，应通知检验工程师。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).材料工程师或检验工程师须对不一致品进行核实。一旦认为是不一致，立即通知检验员或材料检验员将“不一致品扣留标签”（样表A6-01）贴在不一致品上，并填写NCR（不一致品报告）（样表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”.“不一致品扣留标签”上要注明产品编号、NCR号和日期。如果可行的话，将不一致品移到隔离的“扣留”区，然后在“工序检验表”上注明NCR编号。6.3、Determination处置流程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. 材料工程师或检验工程师应对不一致品进行调查，而后将NCR提交给设计工程师、工艺工程师或焊接工程师提出处置方案。最终处置方案应由技术部长审核总工程师批准。The NCR shall be presented to AI for acceptance and for his designation of additional inspection points, where applicable.NCR应提交给AI认可，并在适用时指定额外的检测点。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.不一致品的最终处置需由材料工程师或检查工程师核对，由质检部部长审核，由质保工程师批准并由AI确认。6.4、Disposition处置方法The dispositions of nonconformities are classified into the following cases, s

11、uch as “Reject”, “Use As Is”, “Repair” or “Others”.对不一致品的处置分为几种情况：“报废”、“回用” 、“返修”和“其他”。 6.4.1 “Reject” Disposition“报废”处理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.当不一致品作为“报废/退货”处理时，材料工程师或检验工程师应负责将NCR的复印件分发给车间/仓库等相关部门，通知他们报废情况。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”.材料检验员应负责在

14、有关报废材料的“材料验收记录”上注明“退货”字样；检验员应在直到此阶段为止的有关此报废品的“工序检验表”、报告/记录上注明“报废”字样。材料检验员或检验员还须将“不一致品扣留标签”换成“报废/退货”标签（样表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”.生产部部长有责任将报废材料、部件或产品从工作区域移至“报废区”。6.4.2 “Use As

15、 Is” Disposition“回用”处理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”处理意见以及技术评估须按专业要求由相应的设计工程师、工艺工程师和焊接工程师提出，并须事先征得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.涉及到图纸、计算书和采购文件的更改，按本手册第3和4章所述进行质量控制，包括提交给AI供其审核和认可。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.检验员或材料检验员应将“不一致品扣留标签”换成“回用标签”（样表A6-04），并允许车间进行下一步工序。6.4.3 “Repair” Disposition“返修”处理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.如果需对不一致品进行返修，工艺工程师应组织编制相关的返修程序、“工序检验表”和无损检测要求等。对于常规的焊缝返修，即按AI已认可的程序，采用现有已评定的WPS，并用原无损探伤方法检查，可不作为不一致品，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须经AI审核并在NCR或工序检验表上标上追加的检验点。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.工艺工程师或焊接工程师和检验工程师在最终处理方案已获得技术部长批准和AI认可后，应指导并监督车间进行不一致品的返修。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.对于材料的缺陷，只要其返修方法和范围事先得到AI的认可，就可以进行返修。无法取得满意的返修效果的缺陷材料应判为“报废”。详见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.对于返修完的部件，须按返修及有关程序，由检验员重新检验并记录，检验工程师应再次核查返修结果。只有当检验工程师认定返修合格后，检验员方可去除“不一致品扣留标签”进入下一步工序。NCR和其它相关文件应提交AI审核。6.4.4 “Others” Disposition “其他”处理T