This printed document is an UNCONTROLLED COPY - Check B.O.S.

to verify validity prior to use Date printed: Saturday, July 12, 2008

SOP-0000 Control of Non-conforming Product & Materials

Incidents of known or suspected product or 5.2 Customer Focus

ISO 9001
process non-conformances 7.2.3 Customer Communication
7.4.3 Verification of Purchased Product
may arise or be identified during the 7.5.5 Preservation of Product
implementation of any of the activities identified 7.5.3 Identification & Traceability
Start below (blue boxes). 8.3 Control of Non-conforming Product
8.3.1 Control of Non-conforming Product - Supplemental
The respective controls, responsibilities, and 8.3.3 Customer Information
authority are detailed in the applicable
Work Instructions (red text) identified 4.2 Quality Requirements
4.6 Periodic Re-qualification
Customer-
under each of the individual scenarios 4.16 Customer Feedback specifics

Notification by Process/ Customer / Health &

Receiving Inspection - Supplier Laboratory/Finished
Supplier of defective In-Process Handling / Production Safety Audits, Materials External Returns
Qualification Product Testing
Shipped Parts Management & Housekeeping

Receiver/Quality Assurance Unidentified, unlabelled or

identify & segregate suspect Customer
Production and/or Quality Assurance non-conforming materials returns non-
Quality or non-conforming materials Quality Assurance Personnel identify & Personnel identify or products found during
Assurance during inspection of incoming conforming
segregate known or suspected non- & segregate known Internal/External, Process product or
Department material or supplier conformances or suspected non- or Customer Audits, health
upon notification qualification notifies The
conformances & safety audits, Materials Company of
from Supplier, WI-3043 Isocyanate and Resing Handling Management or by
initiates action to WI-7001 Receiving Inspection WI-3039 Nitrogen Blanketing WI-3040 Preparing Warranty issues
of Raw Materials
housekeeping are resulting in
trace, identify & WI-3044 Resin Agitation Totes Test Specimens
WI-7000 Bulk Tanker WI-5003 Cup Test from Modules
segregated and identified known or
segregate as non-conforming
Offloading WI-5006 Ratio Check WI-5000 Flex suspect Non-
suspect/non- WI-5011 Testing Version WI-5016 Gel Time Test Strength & conformances
conforming Density WI-5002 Process Inspection Modules Test WI-______Process Audit
materials WI-5012 Testing Version Pot WI-3001 Cutting Modules to Length and WI-5001 WI-____ Health & Safety
Customer
WI-____ Life Weighing Interlaminar Shear Audit
WI-5021 Safe Handling of Communication
Processing of WI-5013 Testing Version WI-3009 Drilling Modules – Standard Holes Strength Testing of
Defects Chemicals Customer
Viscosity WI-5005 Physical and Dimensional Tubular Composite Corrective
WI-5014 Testing Isocyanates Inspection Samples WI-7002 Handling and
Storage of Raw Materials Action Request
WI-5015 Testing Version WI-5004 Marking, Drill Hole, Slot Inspection WI-5008 Density,
Resin WI-5007 Module Disposition Void Content and
WI-5018 Receiving Inspection WI-7003 Transfer of Modules Glass Content Test
of Fibreglass WI-7004 Order Preparation
WI-3010 Packaging and Shipping Poles
WI-3045 Cutting Poles to Length & Top
Caps Engineering
WI-3042 Custom Drilling
Annual Validation WI-3014 Preparing Module & Pole ID Tag
Testing WI-5027 Shipment Inspection Engineering Design
change results in
Respective Test/ obsolete materials
Audit results in which must be
identification of non- identified and
conforming product segregated
Floor Plan – Hold Area, SOP-0011
Per Quality
Quarantine Area, Scrap Area Change Control –
Inspection and
Test Plan (QITP) Outdoor Storage Plan
Identification & Segregation Product, Process,
As applicable, Supplier Quality Specialist or Quality Assurance Supervisor Sourcing
ensures suspect or known non-conforming materials are clearly identified &
segregated or moved to designated HOLD/Quarantine area
See CSR…...Type 1 and Type 2

Type 2 Nonconformance
4.2.4 Control of Records notification
Determine disposition Authority
As applicable:
Quality Lab Technician Customer
Inspection Labels communicates
On Hold – FAIL Tag (F-5004)
per applicable Work Instruction assesses suspected or identified non- disposition status
NCR – Quarantine Tag (F-5011) conforming materials/products to determine the Disposition authority and required
Customer Notification/Warranty Type 1 Authority: The Company actions, as
Issue Non-
Customer-specific Requirements
Type 2 Authority: Customer conformance applicable
Customer
(Type 1 and Type 2 Non- Type
communication
nonconformance) Customer to
No Yes
Disposition?

Processing Non-conformances
Quality Lab Technician
per applicable Work Instruction
1) Implements Customer-defined dispositioning instructions or
2) Determines & assigns disposition of one of the following:
- Return to Source - Scrap - 3rd Party Sort
- Rework/reuse - Send to Lab for testing
- Hold - Customer/Internal Waiver Nonconformance Monitoring Records
3) communicates disposition status as applicable to ensure that customers are promptly Customer Waiver
informed of issues which might impact them (Supply Chain Coordinator notifies Disposition Labels, as appropriate:
Go to customer of any actual or potential supplier issues, or potential supply or capacity issues F-5015 Engineering Test Label

A and Q.A. Manager notifies customer of any actual or potential non-conforming product
which may have been shipped)
F-5021 Lab Sample Label
F-5004 On HOLD/FAIL Tag
F-5010 PASS Tag
4) maintains records of the nature of all nonconformities, F-5011 Do Not use/Hold/NCR
(including “suspected nonconformities” which are F-5031 Interim PASS (Orange)
subsequently approved, and any actions taken,
including concessions/waivers obtained)

Patricia Ravanello - Management Systems SOP-0012 Control of Non-Conforming Product and Materials, Revision: 0 Page: 1 of 3
This printed document is an UNCONTROLLED COPY - Check B.O.S. to verify validity prior to use Date printed: Saturday, July 12, 2008

SOP-0000 Control of Non-conforming Product & Materials

As applicable:
Nonconformance Report
Customer Waiver A
Disposition Labels, as appropriate:
F-5015 Engineering Test Label
F-5021 Lab Sample Label
F-5004 On HOLD/FAIL Tag 4.2.4 Control of Records
8.5.2 Corrective Action
F-5010 PASS Tag

Respective Responsible Party takes action to:

eliminate the detected non-conformity
authorize its use, release or acceptance, under concession by a relevant
authority, and where applicable by the customer, or
preclude its original intended use or application
and initiates corrective action per SOP-0000 Corrective and Preventive
Action and Continual Improvement and/or the applicable
Work Instruction as identified below, ensuring that records
of the results of action taken are maintained
- See respective output of
processes (Work
Instructions) identified
below

7.1.4 Change Control

8.3.2 Control of Reworked Product
8.5.2 Rejected Product Test/Analysis

4.2.4 Control of Records

8.3.4 Customer Waiver

Return to Customer/Supplier/Internal
Repair/Rework Scrap/Disposal Design Change Purge
Source Waiver

Quality Assurance ensures

Responsible party
that:
(per applicable W.I.) SOP-0011 Customer Interim
WI-_____ WI-____ WI-_____
identifies instructions for re-work Change Authorization is obtained
Processing of Processing Processing of
identifies re-inspection Control – prior to further processing
Defects of Defects Defects
requirements to ensure Product, whenever the product or
WI-______ WI-______ Purging of process is different from that
effectiveness of corrective Process,
Quarantine Quarantine Raw which is currently approved and
action Source
Area Area Materials that records are maintained of
ensures that the above is WI-7___
Management Managemen In process the expiration date and quantity
accessible and utilized by the Management authorized per
WI-5021 Safe t Finished
appropriate personnel. of Obsolete SOP-0011 Change Control
Handling of Product
WI-_____ Repair/Rework Material WI-5____ Processing
Chemicals Engineering and Document
Management Change Requests

Go
To B

Patricia Ravanello - Management Systems SOP-0012 Control of Non-Conforming Product and Materials, Revision: 0 Page: 2 of 3
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SOP-0000 Control of Non-conforming Product & Materials

B
Metrics DASHBOARD
Non-conformance Monitoring
Records
Rework Records
Scrap Records
Repair Records
Spill Records
Supplier PPM Department Managers
monitor and assess the nature and frequency of non-
conformances per
SOP-0000 Monitoring, Measurement and Analysis
and report analysis and conclusions to
Senior Management per
SOP-0000 Business Planning and Management Review
1) to verify the suitability and effectiveness of the
Business Operating System,
2) to monitor progress toward objectives
3) to assess the need for additional resources, and
4) to identify or evaluate opportunities for continual
improvement
- Management Review Meeting Minutes
(Actions/Responsibilities/Timing)
- Resource Requirements
- Opportunities or recommendations for
continual improvement

End

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