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Document Part No.

Rev Page
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INCOMING INSPECTION PROCEDURE

1.0 PURPOSE

To establish instructions for incoming inspection of specified materials.

2.0 SCOPE & RESPONSIBILITY

The scope of this work instruction is to list, document, and Reference the required procedure for Incoming Inspection of material LOTS. The
Engineering Manager is responsible for the maintenance of this procedure.

3.0 REFERENCES

o ISO_2859: Acceptable Quality Limit (AQL) Incoming Inspection


o NCMR Procedure QA-1069

4.0 DEFINITIONS

4.1 Items exempt from incoming inspection shall be those that are not associated with the development, production, and/ or
quality of manufactured finished good assemblies. Such items include:

• Office Supplies, Consumable, Janitorial Supplies, Educational Materials

4.2 If sample size cannot be determined via the AQL II (2.5), the ENTIRE LOT shall be inspected.

4.3 Unless otherwise specified via explicit inspection requirements for a particular item, items flagged for incoming inspection
shall be inspected to the following SAMPLING PLAN based on ISO 2859 AQL Incoming Inspection

4.4 All Non-conforming Material must be tagged and processed per NCMR process QA-1069

5.0 PROCEDURES

Note: ERP Locations and markings of physical locations are subject to change, shown only for reference.

5.1 Inspect items for shelf life criteria (if applicable) - Receiving

5.2 Flag items for Incoming Inspection - Engineering

• Materials purchased that have parameters and/ or requirements explicitly outlined in Purchase Specifications,
Engineering Specifications, and/ or drawings shall be flagged at the ITEM MASTER level by engineering for incoming
inspection prior to placing in inventory.

5.3 Quality Control notified

• If flagged, QC incoming personnel are notified via email notification that items have been received and are ready
for inspection.

5.4 Items to be inspected & Location

• Items are located near the warehouse receiving area on a shelf marked as “QC INCOMING” material.
• ERP location: is QC-INCOMING_COP/ QC_INCOMING_FIB.

5.5 Adhesive materials

• Located in the “EPOXY PENDING APPROVAL” cabinet located in the indoor fiber production area.
• ERP Location: QC-INCOMING_EPX.

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INCOMING INSPECTION PROCEDURE

5.6 Incoming Inspection Processing

5.6.1 PO Receiving List


• Stored with the physical items in the warehouse incoming inspection staging area. List contains:

1. Incoming PO
2. Item Numbers
3. Received QTYs

5.6.2 The inspection operator shall obtain the PO RECEIVING LIST and applicable QTY of material to be inspected for
the LOT from the staging area and bring the material to the INCOMING INSPECTION quality area located on
the east wall of the main production floor.

5.6.3 Inspection Procedure/Form/Specification

• The path to the applicable inspection procedure, record, and/ or purchase specification is shown below.

Figure 1 – Item Maintenance

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INCOMING INSPECTION PROCEDURE

5.7 AQL II (2.5) Single Sampling Plan

5.7.1 Normal Inspection Levels

• The sample code size chart and sampling plan level for NORMAL INSPECTION levels is provided in Table 1
and Table 2 on the following page. This sampling plan shall be used unless switching rules designate the
use of REDUCED and/ or TIGHTENED INSPECTION levels.

5.7.2 Disposition Criteria

• PASS
1. All units in LOT sample size pass inspection requirements
2. Some nonconforming units are detected within the LOT sample size, but the quantity of non-conformances
is less than the REJECT NUMBER indicated via the AQL SAMPLING PLAN.
• FAIL
1. The number of nonconforming units exceeds the ACCEPTANCE NUMBER within the LOT sample size.

5.7.3 Performing Inspection (Example)

1. The LOT quantity to be inspected is looked up in Table 1 and matched to the corresponding LETTER CODE
for GENERAL INSPECTION LEVEL II (blue circle outline). If reduced or tightened inspection, see Table 3 &
Table 4.

2. Once the LOT LETTER CODE is known, the quantity to inspect for the LOT size is given in the left columns of
Table 2. After locating the sample size to inspect for the LOT, the ACCEPTANCE NUMBER and REJECTION
NUMBER for the sample size can be found by looking under the AQL 2.5 column in Table 2 (blue circle
outline)

3. The tables provided illustrate an incoming inspection example (red and green markings) for a LOT of 1,000
units pending inspection. The LOT total is between 501 and 1,200 pieces (1,000) so the LETTER CODE = J via
Table 1. Looking at Table 2, the sample size to be inspected for LETTER CODE J = 80 pieces.

4. For this sample size the maximum number of nonconforming parts allowed for LOT acceptance = 5 units or
less (ACCEPTANCE NUMBER). If the quantity of nonconforming units = 6 or more (REJECTION NUMBER) the
inspection results in the rejection of the entire LOT.

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INCOMING INSPECTION PROCEDURE

Table 1 - SAMPLE SIZE CODE – NORMAL INSPECTION LEVEL (with example)

Table 2 - SINGLE SAMPLING PLAN – NORMAL INSPECTION LEVEL (with example)

** Markings & arrows on above charts is for example


purposes only. Sample size for inspection will vary with
LOT size

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INCOMING INSPECTION PROCEDURE

5.8 Incoming Inspection Result Recording

5.8.1 Select INCOMING INSPECTION menu from ERP Item Maintenance Menu: Activities/Stockroom
Activities/Incoming Inspection

Figure 2

5.8.2 On the Inspection screen, enter the ITEM RECEIPT PO via PO RECEIVING LIST and browse to the applicable item:

Figure 3

5.8.3 Select appropriate REASON CODE for EACH QUANTITY of units in the LOT SAMPLE that correspond to that
REASON CODE for each disposition scenario listed in section 6.2.4 of this procedure. The scenarios are outlined
again below with the appropriate disposition methodology for each:

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INCOMING INSPECTION PROCEDURE

5.8.3.1 All units in LOT sample size pass inspection requirements

Select OK (Acceptable) REASON CODE and enter QTY for entire LOT SIZE (not the sample size).
Perform MOVE TRANSACTION in ERP system for ENTIRE LOT quantity from QC-INCOMING to QC-
OUTGOING.

Sign off and QC stamp or initial PO RECEIVING LIST and move items to QC-OUTGOING ERP location
and mark physical material in QC-IONCOMING location with QA-1153 QC Outgoing Label. Apply
label to ALL items to alert Material Services physical product is ready for inventory processing. Return
PO RECEIVING LIST to receiving area.

Figure 4 - QC Outgoing Label QA-1153

Figure 5

5.8.3.2 Some non-conforming units are detected within the LOT sample size, but the quantity of non-
conformances is less than the REJECT NMBER indicated via the AQL SAMPLING PLAN.

Select the appropriate FAILURE MODE REASON CODE and enter QTY for the number of units
demonstrating that FAILURE MODE. Perform MOVE TRANSACTION in ERP system for FAILURE MODE QTY
from QC-INCOMING to ME-DISPOSITION.

In addition, Select OK (Acceptable) REASON CODE and enter REMAINING QTY for entire LOT SIZE (not
the sample size). Perform MOVE TRANSACTION in ERP system for ENTIRE LOT quantity from QC-
INCOMING to QC-OUTGOING.

Note – Multiple FAILURE MODES may exist on a single LOT. Perform MOVE DISPOSITION for each
FAILURE MODE QTY in SAMPLE SIZE before moving ENTIRE LOT BALANCE as OK.

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INCOMING INSPECTION PROCEDURE

5.8.3.2.1 Sign off and QC stamp or initial PO RECEIVING LIST and move items to QC-OUTGOING
ERP location and mark physical material in QC-IONCOMING location with “QC
OUTGOING” verbiage or uncontrolled label to alert Material Services physical product is
ready for inventory processing. Return PO RECEIVING LIST to receiving area.

5.8.3.3 The number of nonconforming units exceeds the ACCEPTANCE NUMBER within the LOT sample size.

Select the appropriate FAILURE MODE REASON CODE and enter QTY for entire LOT SIZE (not the
sample size). Perform MOVE TRANSACTION in ERP system for ENTIRE LOT quantity from QC-INCOMING
to ME-DISPOSITION.

Note – Multiple FAILURE MODES may exist on a single LOT. Perform MOVE DISPOSITION for each
FALIURE MODE QTY in SAMPLE SIZE.

Sign off and QC stamp or initial PO RECEIVING LIST and move items to QC-OUTGOING ERP location
and mark physical material in QC-IONCOMING location with “QC OUTGOING” verbiage or
uncontrolled label to alert Material Services physical product is ready for inventory processing. Return
PO RECEIVING LIST to receiving area.

Figure 6

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INCOMING INSPECTION PROCEDURE

5.9 Special Cases

5.9.1 SERVICE ITEMS

Services purchased resulting in a measurable deliverable including CALIBRATION services shall be inspected by
engineering upon receipt to ensure specifications of the requested service have been met.

5.9.2 CUSTOMER SUPPLIED MATERIAL

Unless specified by the customer, custom material provided without specifications shall be except from
incoming inspection requirements and is to be evaluated via the final assembly product testing.

5.9.3 FIRST LOT REQUIREMENTS

The incoming inspection of material LOT from a new vendor (first LOT) shall be performed by a member of the
engineering department to ensure no additional inspection requirements are required for future LOT deliveries.

5.9.4 TOOLING & EQUIPMENT

Production tooling and equipment for production, quality, or engineering use shall be inspected prior to
RELEASE through the Tooling & Equipment Commissioning Process (ENG-1070)

5.10 Switching Rules for Reduced & Tightened Inspection Levels

5.10.1 Those vendors classified as VERIZON APPROVED suppliers shall be subject to switching rules for incoming
product LOTS allowing for reduced inspection levels or potentially tightened inspection levels based on LOT
acceptance performance.

5.10.2 The tracking, calculating, and updating of the switching score shall be managed in re-occurring management
meetings where vendor inspection summaries are reviewed. Alternative inspection levels shall be indicated at
the PO level and indicated on the PO RECEIVING LIST.

5.10.3 Any VERIZON supplier with zero (0) non conforming LOT’s for a period of 60 days shall be subject to reduced
sampling. A single non conforming LOT shall return the supplier to NORMAL sampling. If the supplier is currently
on a NORMAL sampling plan, a single non conforming LOT in 60 days shall subject the supplier to TIGHTENED
sampling. Finally, while on TIGHTENED sampling a supplier may return to NORMAL sampling after 60 days of zero
(0) non-conforming LOT’s.

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INCOMING INSPECTION PROCEDURE

Table 3 - Reduced Single Sampling Plan – AQL II (2.5)

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INCOMING INSPECTION PROCEDURE

Table 4 - Tightened Sampling Plan – AQL II (2.5)

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INCOMING INSPECTION PROCEDURE

5.11 Incoming Inspection Reporting Summaries

5.11.1 Incoming inspection report summaries by vendor and date range may be reviewed via company intranet on
DASHBOARD 2 under the MANUFACTURING tab.

5.11.2 Inspection report summaries shall be reviewed periodically for vendor performance maintenance and the
application of switching rules for material received from VERIZON APPROVED suppliers.

Figure 7

5.12 AQL Inspection Selection Rationale

5.12.1 Selection of the AQL was based on the 6 month review of the incoming inspection performance of our vendors.
Using vendor performance history, it was determined that the AQL of 2.5 will provide the most appropriate A/R.

Table 5
Total Lines
Period / Fiscal Year Total Lines Percentage Rejected
Rejected

P1 FY13 1225 1 0.082%


P2 FY13 1027 5 0.487%
P3 FY13 1419 6 0.423%
P4 FY13 1537 1 0.065%
P5 FY13 1248 2 0.160%
P6 FY13 1229 1 0.081%
P7 FY13 1273 2 0.157%
P8 FY13 1410 0 0.000%
P9 FY13 1375 3 0.218%
P10 FY13 1513 1 0.066%
P11 FY13 1235 1 0.081%
P12 FY13 1220 1 0.082%
12 Month
Average 15711 24 0.159%

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