CDS1301-W1 Rev. S - NCR PROCESS

SAVE OFFLINE

CABIN

NCR PROCESS

Work Instruction IDENTIFICATION Document No.:

CDS1301-W1

QMS Process:

Evaluate and Improve

Revision:

S

Applicability:

Contracts, Engineering, Materials, Operations, Quality

SUMMARY Instruction on how to complete non-conformance reports within the R5 software system.

VALIDATION

Name and function

Signature

Date

Written by

Terri Gonzales QMS Manager

See Companies Standards database workflow for approval

11 Jan. 2019

Approved by

Bill Finch VP of Quality

See Companies Standards database workflow for approval

23 Jan. 2019

SAFRAN CABIN INC. 5701 Bolsa Ave. Huntington Beach, CA 92647

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NCR PROCESS CDS1301-W1 - Revision: S

LIST OF CHECKERS BUSINESS UNIT

NAME

POSITION

OIB CIM CCB CCB CMC CSS CBI CCB CCI

Andre Moreno Jose Gabriel Rodriguez Angelica Varela Robert Cooper Lesliegh Kahre Victor Munoz Steven Cowling Mike Valeriano Andre Donatt

Quality Manager Quality Director Quality System Specialist Quality Manager Quality Manager Quality Manager Quality Engineering Supervisor Quality Director Quality Manager

REVISION LIST REVISION

DATE

A

12/15/00

To conform to NCR form changes (pg.11)

T. Titone

B

5/21/01

Revised NCR (pg.11) and Codes (pg.13)

T. DeFrancisco

C

5/2/02

Removed reference to colored copies from 5.9 , 7.1, 7.5

T. DeFrancisco

D

9/10/03

T. DeFrancisco

E

2/20/04

F

11/15/04

G

9/5/05

Corrected 3.0 Ref. Docs; Sec. 5.9 change to “Customer Property”. Forms changed from 4 copies to 3. Added clarification to sec. 6.5, & a requirement to Field #38 instructions (pg. 9) Added rqmt’s to record RMA no. on NCR; Ref. field 21 pg. 8. Code 20 NCR’s to accounting; ref. 5.6 & 7.5 All references to company name, changed to C&D Zodiac, Inc. Added pg. 13

H

3/29/06

Added codes to pages 12 & 13

T. DeFrancisco

J

6/29/07

Revised facility designations in sec. 8.0 to match Royal 4. Added info to sec. 6.0

T. DeFrancisco

K

7/27/07

Revised 5.0 to clarify customer MRB procedures

T. DeFrancisco

L

3/1/09

Created new web based CDS1301-W1-F1 form and procedure

M

10/30/09

N

03/02/10

P

09/12/12

Q

2/2/2017

R

10/29/2018

S

01/11/2019

DESCRIPTION OF THE CHANGE

Removed all procedural instructions and placed in CDS1301 and updated instructions for web based NCR system per SCN 1301-W1. Revised sections 5.0 through 13.0 to reflect recent changes to the WEB based NCR system. See SCN N1 for details. Revised all references to previous ERP system Royal 4 and updated all relevant information to R5 as applicable. Move NCR category to definition section. Clarify meaning of NCR closure section 8.0. Add new section for NCR administration in R5.Change template Revise work instruction to provide guidance that reflects R5 development updates: incorporation of squawks and low cost scrap. Release CDS1301-W1-F2, Supplemental Nonconformity Traceability form. Update template due to Safran re-branding project. Replace company name as needed throughout document.

Revise Section 11. due to issue that resulted in an NoE and a Major SER from Boeing. Updated as follows: Only the new NCR’s, which have not been moved from the Inspector to any other NCR Work Group, can be deleted. Any NCR that has already been submitted to a customer MRB authority for review, but that we would later like to void / delete would need the full approval of the same MRB authority documented before we are able to internally void the NCR."

PREPARED BY

T. DeFrancisco T. DeFrancisco T. DeFrancisco

E. Godinez E. Godinez E. Godinez

J. Delgado

F. Leonards

F. Leonards

T. Gonzales

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NCR PROCESS CDS1301-W1 - Revision: S

TABLE OF CONTENT 1

PURPOSE ..................................................................................................................................................... 4

2

SCOPE .......................................................................................................................................................... 4

3

REFERENCE DOCUMENTS ........................................................................................................................ 4

4

DEFINITIONS AND ACRONYMS ................................................................................................................. 4

5

CREATING AN NCR ..................................................................................................................................... 5

6

NCR DISPOSITION ...................................................................................................................................... 11

7

ADDITIONAL INFORMATION ...................................................................................................................... 13

8

NCR BUYOFF ............................................................................................................................................... 14

9

NCR NOTES ................................................................................................................................................. 15

10 NCR PRINT ................................................................................................................................................... 16 11 DELETE OR VOID NCR ............................................................................................................................... 17 12 OPEN NCR INQUIRY ................................................................................................................................... 18 13 NCR INQUIRY AND REPORT ...................................................................................................................... 19 14 NCR MAINTENANCE ................................................................................................................................... 21

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NCR PROCESS CDS1301-W1 - Revision: S

1

PURPOSE

This work instruction describes the process of completing a Non-Conforming Report (NCR) in R5 (web) and identifies the personnel responsible for completion.

2

SCOPE

This document applies to all products, before shipping and upon return, that fail to conform to requirements specified in the contract, specification or other applicable product description per CDS1301 Control of Nonconforming Product.

3

REFERENCE DOCUMENTS DOCUMENT NUMBER

TITLE

CDS1301

Control of Non-Conforming Product

CDS1301-F1

Red Tag

CDS1301-W1-F1

Non-conforming Report (NCR)

CDS1301-W1-F2

Supplemental Nonconformity Traceability

CDS1301-W3

Material Review Board

CDS1301-W4

Product Return Process

CDS1402

Corrective Action

4

DEFINITIONS AND ACRONYMS ACRONYM / WORD

Major non conformance

Minor non conformance

DESCRIPTION A non-conformance that adversely affects any of the following: a) Health b) Performance c) Contract specified system requirements affecting interchangeability, reliability or maintainability d) Effective use or operation e) Weight or appearance (when a factor) f) Non-conformances pertinent to parts/assemblies classified as safety of flight, critical, fracture and/or maintenance critical, fracture critical traceable, durability critical parts or assemblies. Non conformances that are not major.

*** For other definitions reference CDS0502-W1 Glossary of Words/Terms ***

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NCR PROCESS CDS1301-W1 - Revision: S

5

CREATING AN NCR

Click on the R5 folder located in the R4 Web Live from the Intranet or from Safran Cabin Inc. Home page or manually enter the URL address via your internet browser application is http://r5.cdzodiac.com/

Enter your Windows account and password (or the system will automatically log you on based on the windows authentication check):

Select Quality Assurance from the main menu.

5.1 How to ent e r a new NC R, Squ aw k o r L ow Cos t S cr ap re co rd To enter an NCR, Squawk or Low Cost Scrap record in R5 select “Non-Conforming Report”

Select “Add” from the search page to initiate a new record.

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NCR PROCESS CDS1301-W1 - Revision: S

5.1.1

NCR Header Entry:

When the new record appears, enter the following information in the Header form as available and required.

NCR No. – will be system generated. Date – defaults to the current date. Part Number – enter M3 part number. To search for a part number click on the icon, enter a partial part number or description, followed by an asterisks and click “Submit”. Click on the desired Item Number.

Description – auto populated by the system. Customer Code – enter the code or use to search by Customer Name. This field is not mandatory. Customer Name – auto populated by the system. Customer Ref. Number – customer Reference number should be entered only when available. RMA – enter Return Material Authorization number if applicable. Location – enter location where the Item can be found. Inspector’s I.D. – auto populated by the system Inspector’s Name – auto populated by the system, based on the login name entered above. Aircraft Model – select the applicable entry from the drop down list when known (this field is optional) SAFRAN CABIN INC. 5701 Bolsa Ave. Huntington Beach, CA 92647

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NCR PROCESS CDS1301-W1 - Revision: S

Record Type – select the appropriate record type per CDS1301. The system default value is “NCR”. Initial Department – enter the number of the department where the NCR was initiated (ref. CDS1301-W2) Upon completion of the “Header” form, click Save so the system will display the NCR view screen.

5.1.2

NC R T r ac e ab ili t y N u mbe r Ent r y

Click on view screen

in the NCR

Traceability Number – usually equals Lot number, although there are exceptions. These exceptions are described in the ‘Type’. Type – There are Traceability Types:

four

I.

Rcpt Ln – Receipt Line number applies to purchased Items

II.

RMA – Return Material Authorization number should be entered for all rejected product. Please note that RMA number entered in the Traceability field must be the same as the RMA number entered in the header of the NCR (ref. CDS1301-W4)

III.

MOA – Made On Assembly; applies to the ‘phantom’ items, manufactured without the Work Order. In this case a Work Order number for the Parent Item should be entered

IV.

MO Lot Number – Work Order number applies to manufactured Items

Rev – Lot revision number will be populated by the system if found. It can be entered manually for MOA and RMA Types. SAFRAN CABIN INC. 5701 Bolsa Ave. Huntington Beach, CA 92647

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NCR PROCESS CDS1301-W1 - Revision: S

Lot Qty – will be auto populated by the system for Rcpt Ln and W/O Types. It has to be entered manually for the two other Types. Rej Qty – required field designating the total number of units rejected for the lot in question. A/C No. – will be auto populated by the system when found and can be entered manually. Final Department – will be populated by the system when Type entered equals W/O or Rcpt Ln. Final Department equals Entity Code of the Department which manufactured or purchased the Item. Vendor Code – will be system populated for purchased Items or the ones being subject of the Inter-company stock transfers. It can also be entered manually. Vendor Name – will default to the Name associated with the Vendor Code. After Traceability Number information is filled out, click on . You will be able to enter more Traceability Numbers now. Please keep in mind that all Traceability Numbers entered for the same NCR must be of the same Type and they must be related to the same Final Department. If the NCR is written against an Outside Process performed by a vendor, use the MOA traceability type.

If the Traceablility Number has been entered in error, click on the ‘radio’ button . When all the numbers are entered, click on

and then on

next to that Lot and then on .

5. 1. 3 NC R Di sc r ep an c y Ent r y In order to enter Discrepancies, click on Click on

in the NCR view screen.

. This will create the first discrepancy number ‘1 of 1’: Complete the form appropriately.

Discr. Qty – enter discrepant quantity related to the first discrepancy. Discrepant quantity cannot exceed total Lot quantity Commodity – click on and select appropriate Commodity code Process – click on and select the Process code Disc. Trace No. – field that auto populates with a unique discrepancy number Noun – click on and select Discrepancy Noun code Adjective – click on and select Adjective code related to the Noun SAFRAN CABIN INC. 5701 Bolsa Ave. Huntington Beach, CA 92647

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NCR PROCESS CDS1301-W1 - Revision: S

CAR Reqd – this field has two options, and . If you select , CAR number will have to be entered prior to closing of the NCR Lot Trace No. - click on and select the appropriate lot number from the drop down list CAR No. – to be entered if CAR is required Cause – click on and select desired code Responsibility – click on and select desired code Description – enter Discrepancy description Click on

if there are more discrepancies to be entered, click

, otherwise, click

.

At this point, an inspector entering a new NCR can attach Documentation related to the NCR Discrepancy or can sign off, moving the NCR to the next stage. 5. 1. 4 At ta ch ing D ocu m ent s In order to attach Documentation to the NCR, click on

in the NCR view screen.

Make sure that you are in the correct discrepancy number. Click on

and find the file which needed to upload into the NCR.

NO T E: At t ac h th e S up p l em ent a l N onc o nf orm it y T r ac e a b il i t y f o r m (CD S1 3 01 -W 1- F2) o r r e work m an uf ac t ur i ng or d er ins tr uc t i ons NC Rs a nd S qu a wk NC R Rec or ds i n or d er t o r e ta i n trac e ab i l it y of s p ec if ic ac t io ns t a k en t o c orr e c t no nc onf orm anc es . Click on

.

Add as many documents as needed before clicking on In order to delete a document, highlight document name and click 5. 1. 5 Ins pe cto r ’s B u y O f f

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NCR PROCESS CDS1301-W1 - Revision: S

In order to pass a new NCR entered by an Inspector to another work group, required fields in Header, Lots and Discrepancy have to be filled out. Click on Click on

in the NCR view screen: in the ‘Move To’ field

Move To – the following stages are available in the drop down list: - Inspector - Eng/MRB - Prg Manager - Stress - Flam - CNC - Purchasing - Planning - QA/MRB - Customer - QA Stamp - Closed User I.D. – enter the user’s windows account of the person (i.e. ‘na\jdoe’) who will sign off selected stage of the NCR. If you do not know the user’s windows account, click on

to search:

NOTE: Low Cost Scrap and Squawk Records may be moved to QA Stamp directly by the QA Inspector.

Select user Work Group and click on

Click on the User Name. User network account will be auto populated in the Sign Off screen. E-Mail – if you select , the person defined in the User I.D. field will receive automatic e-mail notification about pending status of the NCR.

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NCR PROCESS CDS1301-W1 - Revision: S

Click on

then click on

.

Enter your network account password and click on

.

Click on

.

New Status of the NCR, Due Date for the Sign off and Network Account Name is displayed in the NCR view screen now. Click on

6

.

NCR DISPOSITION

NO T E: T h e Dis p os it i o n a n d D is p os it i on C o de f or L o w C os t Sc r ap a n d Sq u a wk rec or ds is au t om atic a l l y u p da te d b y t he s ys tem . T h e Q A I ns pec t or wi l l n ot b e a b le to m od if y t h e c on t en t i n t h es e f ie l ds . T he S up p lm en ta l No nc onf or m it y T rac e ab i l it y f orm (CD S 1 30 1 -W 1- F2) m a y b e us e d t o c a pt ur e s pec if ic i ns tr uc ti o ns , etc . ne ed e d to f u lf i l l t he d is p os it i on . 6.1 How to Disposition an NCR Each user who is designated to disposition or sign off the NCR should receive e-mail notification:

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NCR PROCESS CDS1301-W1 - Revision: S

After logging in, select “Non-Conforming Report” from the main menu.

Division – defaults to your login entity. If the NCR to be dealt with is in a different entity, select it from the drop down list. NCR No. – if you want to select a particular NCR, enter its number. User I.D. – by entering your own network account I.D., you can select NCR’s pertaining only to you. Pending Status – selection from the drop down list allows choosing only a particular stage of all NCR’s. Final Department – entity code of the Department which manufactured or purchased Part Number being subject of the NCR. Part Number – if entered in this field, the system will display all NCR’s (in selected Division) for that Part Number only. Click on

. If no particular selection is made, the system will display all open NCR’s in the login Division:

Click on the ‘radio’ button

next to the NCR number to select an NCR from the list shown above. Click

.

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NCR PROCESS CDS1301-W1 - Revision: S

Click

.

Disposition – enter the text of the disposition. ECN Reqd – this field has two options, and . If is selected, ECN number, its Revision Number and its Date should be entered prior to closing of the NCR (it is not mandatory, though) ECN Rev – ECN Revision number to be entered if ECN is required ECN Date – to be entered if ECN is required Disp. Code – select from the drop down list. Category – select from the drop down list (refer to the definitions in section 4.0) NOTE: Category ‘Major’ requires sign off by the Customer (when applicable). Click . If there is more than one Discrepancy, use arrow buttons Each Discrepancy must have a disposition.

to move between Discrepancies.

When finished, click on NOTE: The Supplemental Nonconformity Traceability form (CDS1301-W1-F2) may be used to help carry-out dispositions as needed.

7

ADDITIONAL INFORMATION

This window will enable Program Manager or QA/MRB to enter the cost of the NCR. It will also allow the Planner to enter Rework Work Order number, if needed. Click on

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NCR PROCESS CDS1301-W1 - Revision: S

Rework W/O – enter rework Work Order number if the Disposition is Rework. Work Order number has to be entered prior to closing of the NCR Admin Cost – NCR Administrative Cost is auto populated by the value determined in the control file for a given facility. Item Cost – when you click in the item cost field, the system will display standard cost of the Item:

Click on

if you want to apply the standard.

Click on

if you want to enter a value different than std. cost.

For disposition code ‘Return to Vendor’ and ‘Use As Is’ Item cost should be “0”. For ‘Scrap’ Item cost should be the full std. cost. For Repair and Rework, Item Cost should be calculated. Return to Vendor Information – the Buyer should enter information related to the return of the discrepant Lot to the Vendor. Shipping Documents should still be attached in the Documentation section of the NCR. The NCR should not be closed until the Buyer states that the Vendor agreed with our Responsibility Code. When finished, click on

8

and then on

NCR BUYOFF

8.1 Please refer to section Inspector’s Buy Off section 5.2.5. The same procedure applies to all users signing off an NCR. If the NCR is to be signed off by a Customer, in the User I.D. field show the person who is responsible for submitting the NCR to the Customer and getting their approval. Once the Customer’s approval is obtained, the same person is responsible for moving NCR to the next stage. 8.2

If the NCR has to be reassigned to a different user, click on

in the buyoff screen:

NO T E: Lo w Cos t Sc r a p a nd Sq u a wk r ec or ds s o l e l y r e qu ir e Q A I ns pec t or an d Q A S tam p bu y of f pr io r t o rec or d c l os ur e wi th i n t h is s ys tem . Existing user:

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NCR PROCESS CDS1301-W1 - Revision: S

Replace existing User Group (Move To), if applicable, and the User I.D. and click on described in section 5.2.5.

. Follow procedure

Users who are signing off as Eng/MRB and QA/MRB must be the members of the Material Review Board. If changes are needed, the NCR can be moved back to any of the users who have already signed it off. Inspector designated in the QA Stamp stage is responsible for the final checking of the NCR and moving it to the stage ‘Closed’. An NCR is closed only after the disposition has been carried out and verified by the designated inspector. Note: The NCR cannot be closed if any of the Lot numbers listed in the NCR are still in the MRB Bin:

9

NCR NOTES

If there is a need to communicate a message to another user on a particular NCR, Notes function should be used:

Click on the Notes Button for the NCR. Enter the text of the note. If NCR is urgent, click on the ‘Rush’ check off box. SAFRAN CABIN INC. 5701 Bolsa Ave. Huntington Beach, CA 92647

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NCR PROCESS CDS1301-W1 - Revision: S

Click on Note button will change to button will change to solid red

10

, indication that there is a note entered. If the ‘Rush’ box was checked off, the Note if there is no note entered, or if there is a note entered.

NCR PRINT

To print NCR, in the NCR view screen, click on

Click on

. Select “Open”;

to print NCR

In order to print documents attached to the NCR click on

in the NCR view screen:

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NCR PROCESS CDS1301-W1 - Revision: S

Click on the Document to be printed. Click on. opened, print it.

11

Once the document is

DELETE OR VOID NCR

Only the new NCR’s, which have not been moved from the Inspector to any other NCR Work Group, can be deleted. Any NCR that has already been submitted to a customer MRB authority for review, but that we would later like to void / delete would need the full approval of the same MRB authority documented before we are able to internally void the NCR."

Click . Click when prompted. NCR will be removed from the NCR list.

NOTE: No NCR’s, which have more than just Inspector’s signature, can ever be deleted. When absolutely necessary they can be voided though. Only NCR Administrator and the QA Manager will have access to the ‘Void’ function.

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NCR PROCESS CDS1301-W1 - Revision: S

Click on

Click on

to enter the Void Reason

Enter the Void Reason and click on

Void reason will be displayed in the Disposition section of the NCR. User I.D. and date stamp will be inserted by the system, automatically. Click on Once the NCR is voided, it will be available for viewing only in the NCR Inquiry (WQA 4 5).

12

OPEN NCR INQUIRY

Log into R5 Web and go to Non Conforming Report in the Entry sub-menu (WQA 2 2).

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NCR PROCESS CDS1301-W1 - Revision: S

This screen shows all open NCR’s. It displays the NCR number and it’s date, Part Number, Pending status, the name of the user to whom the NCR is assigned, Time Elapsed and the Notes. Time elapsed is calculated from the time stamp when the NCR was assigned to the user shown in the screen above. This list can be printed by pressing

13

button:

NCR INQUIRY AND REPORT

Log into R5 Web and go to “NCR Inquiry” from the main menu. Fill out required parameters and click

Following is the list of the NCR status codes: New – NEW Inspector - INS Engineering - ENG Program Manager PGM

Stress - STR Flammability - FLM CNC – CNC Purchasing - PUR Planning – PLN

QA Manager – QAM Customer – CUS QA Stamp – QAS Closed – CLD Void – VOD

To view or print a particular NCR, click on the ‘radio button’ next to the Division and NCR Number. Click

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NCR PROCESS CDS1301-W1 - Revision: S

NCR view screen is displayed, where no editing is allowed There are also

and

button available in the View version of the NCR.

To print a range of NCR’s, it is important to narrow down the list of the NCR’s to be displayed in the Inquiry. Most common would be selection of a date range, particular Customer or the Vendor code

Click on

button.

PDF File will be displayed on your screen. If you want to print the report click on If you want to print a report on the selected NCR’s click on

PDF File is displayed on your screen. If you want to print the report click on If you want to export a report on selected NCR’s, you will have two options difference between two options is shown below:

or

. The

NCR BL001255 has three Traceability Lot numbers and two Discrepancies: SAFRAN CABIN INC. 5701 Bolsa Ave. Huntington Beach, CA 92647

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NCR PROCESS CDS1301-W1 - Revision: S

Therefore, six records are created (2 discrepancies per each Lot). These are the records which

will print out:

Please note that not all fields of the report are displayed above. Export function will display every field of the NCR. will combine all Traceability Lots into one line per each Discrepancy

Summary Export displays all fields from the NCR, including ‘Time Elapsed’ for each NCR signature and the Total time it took to complete the NCR. The total time is displayed only for ‘closed’ NCR’s:

14

NCR MAINTENANCE

Once logged in to R5 click on Quality Assurance. The ‘Entry’, ‘Maintenance’ and ‘Inquiry’ screen will open and offer the functions as shown here.

Select the function that needs to be updated.

14.1

NCR User Maintenance

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NCR PROCESS CDS1301-W1 - Revision: S

Enter the network user-id and then click ‘Submit’. NOTE: A list of all R5 users can be exported by facility.

Click the drop-down menu to assign the user with the proper class. To remove the user from the class, please select the ‘- Select Class –‘option.

The

option will allow users to export the current selected user-id to an Excel file. NCR User Permissions Userid

UserName

Role

RoleId

Facilities

NA\JHo

Jonathan Ho

NCR Administrator

10

C90,C80,C30,C20

NA\JHo

Jonathan Ho

NCR Administrator

10

C90,C80,C20

NA\JHo

Jonathan Ho

NCR Administrator

10

C90,C80,C20,C30

NA\JHo

Jonathan Ho

Program Manager

8

C50

NA\JHo

Jonathan Ho

QA Inspector

1

C30

NA\JHo

Jonathan Ho

QA Manager

9

C30

(Notes: All users will have access to the NCR User maintenance function, but only authorized users will be able to assign user class, otherwise everyone has access to the 14.2

option).

NCR Cost Maintenance

Enter a specific facility or ‘All’ for all facilities and then hit ‘Submit’. All users will have access to the NCR Cost maintenance function, but only authorized users will be able to edit ( ), delete ( ) and create new record, otherwise everyone has access to the

option.

SAFRAN CABIN INC. 5701 Bolsa Ave. Huntington Beach, CA 92647

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NCR PROCESS CDS1301-W1 - Revision: S

14.3 NCR Discrepancy Noun & Adjective Relationship Maintenance Enter a specific noun or ‘All’ for all nouns and then hit ‘Submit’. All users will have access to the NCR Discrepancy Noun & Adjective Relationship maintenance function, but only authorized users will be able to delete ( ) and create new record, otherwise everyone has access to the option.

14.4 NCR Code Maintenance Select a specific discrepancy type with optional code and then hit ‘Submit’. All users will have access to the NCR Code maintenance function, but only authorized users will be able to edit ( ), delete ( ) and create new record, otherwise everyone has access to the

option.

SAFRAN CABIN INC. 5701 Bolsa Ave. Huntington Beach, CA 92647

Page 23 / 23

This document and the information it contains is the property of Safran. It may not be used, reproduced or transmitted to a third party without prior written approval.