N. Control of Non-Conformance¶
1. Purpose¶
Non-conformance is when product does not meet the drawing requirements or contract specifications. Product non-conformance can be material or processes. When the Quality Control Inspector (QCI) or Quality Control Manager (QCM) deems the material is in non-conformance, the material will be removed from the fabrication process for identification, documentation, evaluation, resolution and disposition.
2. Definitions¶
For readability, this section uses the following definitions and abbreviations.
- 2.1 Non-conformance: When something does not meet the specification or requirements in some way. Non-conformance is not limited to a non-conforming product. Non-conformance can be in a service, a product, a process, from a supplier, or in the system itself.
3. References¶
- 3.1 Seacoast Inc. Quality Control Plan (Section A)
4. Responsibilities¶
- 4.1 Owner of Process: The quality control manager will review and approve any changes to this procedure. The procedures will be reviewed periodically at a minimum annually.
- 4.2 Quality Control (Manager): The quality control manager will approve the final procedures before deployed to the Quality Manual. Quality control manager is also responsible for resolving the non-conformance so that a conforming product is delivered.
- 4.3 Shop Foreman: Responsible for following this procedure and ensuring the procedure is followed by all shop Staff.
- 4.4 Shop Staff: Responsible to follow this procedure and report all non-conformances.
5. Quality Records¶
Unless otherwise noted, all Quality Records follow the Seacoast "Policy for Maintenance of Quality Records" documented in the QCM Quality Control Plan (Section A-page 13)
- 5.1 Non-Conformance Log (NCL1): Information retained for 2 years.
- 5.2 Non-Conformance Tag: Retained until the non-conformance is resolved.
6. Documentation¶
6.1 Non-conformance Definition¶
A non-conformance is when something does not meet the specification or requirements in some way. Non-conformance is not limited to a non-conforming product. Non-conformance can be in a service, a product, a process, from a supplier, or in the system itself.
6.2 Product Non-conformance¶
| Step | Description |
|---|---|
| 1 | The non-conforming piece is tagged and taken out of production. The tag will show the date, piece mark, a brief description of the problem. The tag remains with the piece until the non-conformance is resolved. |
| 2 | Shop staff reports the non-conformance to the shop foreman and/or to the quality control manager. |
| 3 | The shop foreman or quality control manager in consultation with the detailer/engineer decide the treatment of the non-conformance |
| 4 | The non-conformance is captured on the non-conformance log (NCL1), see the procedure "how to log a non-conformance" |
| 5 | If the non-conformance is "use as is", the quality control manager or their designee notifies the job superintendent (and others if required) of the non-conformance via email. |
Step 3 — Disposition Options:
| Disposition | Description |
|---|---|
| Repair | To be re-inspected per contract documents. |
| Use As Is | After approval by the engineer or owner (QAI - Quality Assurance Inspector). |
| Scrap | When the non-conformance material is not accepted in writing from the owner. |
6.3 Process Non-conformance¶
| Step | Description |
|---|---|
| 1 | Staff member reports the non-conformance to the quality control manager. |
| 2 | The quality control manager in consultation with appropriate interested parties decide how to remedy the non-conformance. |
| 3 | The non-conformance is captured on the non-conformance log, see "How to log a non-conformance" |
6.4 How to Log a Non-conformance¶
The quality control manager is responsible for ensuring non-conformances are captured in the non-conformance log.
| Step | Description |
|---|---|
| 1 | A non-conformance needs to be captured |
| 2 | Locate "Shop Board Current" file on the Seacoast Google shared drive and open the file Seacoast Google Share (Drive) >> Shop Board (folder) >> Shop Board [Current Year] (file) |
| 3 | Open the file Shop Board [Current Year] (file) and select the NCL1 (tab) |
| 4 | Enter the required information |
| 5 | The information captured is used to identify trends which are reviewed through the Management Review Meeting (MRM) Quality Assurance process. |
Step 4 — Non-conformance Log Fields:
| No | Label | Description |
|---|---|---|
| 1 | Job | The Seacoast, Inc. Job number |
| 2 | Date | Date the non-conformance was identified |
| 3 | Dwg # | The drawing number being worked on |
| 4 | Piece Mark | The piece mark of the non-conforming item |
| 5 | Problem/Reason | What is the nature of the non-conformance (i.e. drilled wrong hole size) |
| 6 | Root Cause | What was the underlying reason for the non-conformance (i.e. read prints wrong) |
| 7 | Final disposition | What to do about the non-conformance (i.e repair, scrap, use as is) |
| 8 | Reinspection | How was the non-conformance corrected |
| 9 | Rpr Hrs | How long it took to correct the non-conformance |
| 10 | Pc lbs | How much the piece weighs from the drawing |
| 11 | Extra Matl Cost | Calculated field based on the piece weight in lbs multiplied by $0.40 if the original piece must be scrapped |
| 12 | Total Cost | Calculated field that adds up [repair hours multiplied by $50] plus [material cost, if the original piece must be scrapped]. |
| 13 | Fabricator | Who performed the task that resulted in the non-conformance |
| 14 | Checker | Who checked the piece |
| 15 | Identified by | Who identified the non-conformance. |
7. Revision History¶
| Revision Date | Approved By |
|---|---|
| 2026-05-12 | Quality Manager |
Summary of Change: Reformatted to standard procedure template.