WKPP Procedure No. QA-001 Rev.

0 Page 1 of 5
QA Team Date December 2, 2011
Title PROCESSING NONCONFORMANCE
REPORTS

1 . SCOPE

1.1. This procedure describes the preparation, disposition, approval and distribution of
nonconformance reports (NCR).

1.2. A nonconformance is a deficiency in plant material, equipment, structures, or processes that

renders the quality unacceptable.

1.3. This procedure applies to both on-site activities and vendor shop activities.

2. PROCEDURE

2.1. NCR Preparation

2.1.1. Any QA Team member, WKPP employee or other site team member discovering a
nonconformance shall document its existence by completing a non-conformance
form, Exhibit 1.

2.1.2. Individuals initiating the NCR shall complete blocks 1 through 5. The NCR number
shall be obtained from the QA Team technical assistant (TA).

2.1.3. The initiator shall provide a description of the nonconformance in block 6.

References to a specification section, drawing or other design document or an
accepted practice should be included Additional sheets or photographs may be used if
needed.

2.1.4. The initiator shall mark block 7 with NCR category.

1 - Correct immediately. Stop work if necessary.

2 – Correct prior to Mechanical Completion

3 – Correct prior to Final Completion

2.1.5. The initiator may propose a recommended solution in block 10 of the NCR.
 Otherwise the resolution will be provided by the responsible organization (Wartsila,
Keir, K-Line).

2.1.6. The initiator may request independent verification of the non-conforming condition
by selecting “Yes” in block 9. The initiator and reviewer shall resolve any issues
identified during the review.

2.1.7. The initiator shall initial the NCR in block 1 and submit to the TA for log-in and
internal QA Team distribution.

2.1.8. The initiator shall forward the NCR to the project administrator for distribution of the
NCR.

2.1.9. An NCR log (Exhibit 2) shall be maintained by the QA Team Technical Assistant
(TA)

2.2. NCR Disposition

2.2.1. The QA Team leader will review each NCR and make any necessary changes. The
final version of the NCR shall be sent to the engineering / construction organization
that is responsible for the work.

2.2.2. Upon receipt of the NCR the responsible organization will assign a cognizant
engineer who will either accept the recommended disposition or will propose a
different disposition. The cognizant engineer shall describe the remedy he proposes
in in block 10 and attach drawings or documents as necessary.

2.2.3. In block 11 the cognizant engineer shall categorize his proposed disposition as:
A. Rework or Repair - the items so that they can function reliably
and safely even though it does not meet originally specified
requirements.
B. Replace – with a new or equivalent item so that it can reliably and
safely perform its intended function.
C. Use-as-is - accepting the items when it has been established that the
nonconformance will result in no adverse condition and that the
item will continue to meet all other specified requirements

2.2.4. The cognizant engineer shall record in block 12 the persons responsible for the
corrective actions and the required completion date.

2.3. Review
 2.3.1. The TA will log the completed response and the QA Team will review the proposed
disposition.
2.3.2. If the proposed disposition is unacceptable the QA Team will return the NCR to the
Responsible Organization with recommendations for rework.

2.3.3. If agreement cannot be reached the NCR will be held as In Dispute and added to the
punch list for resolution prior to final completion.

2.4. Approvals

2.4.1. After the proposed disposition has been accepted by the QA Team, the Owner’s
Engineer will sign the form in block 13.

2.4.2. The TA will record the QA Team approval in the log and maintain custody of the
completed NCR.

2.4.3. Copies (PDF) of the signed NCRs shall be distributed by the TA to the responsible
organization and WKPP management personnel.

2.5. NCR Disposition Verification

2.5.1. The QA Team shall verify that the corrective action is completed as specified. This
shall be accomplished by actual inspection of item or review of vendor/subcontractor
documentation.

2.5.2. Upon verification, the Owner’s Engineer shall close out the NCR by signing in block
15. The close out date shall be recorded in the NCR log.

2.6. Distribution

2.6.1. Copies (PDF) of the signed NCRs shall be distributed by the TA to the responsible
organization and WKPP management personnel.

2.6.2. Originals of the completed NCRs shall be maintained by the TA as project QA

records.

4.0 RECORDS

4.1 NCRs shall be filed in the project files.

4.2 The log of NCR shall be filed in the project files.

 Exhibit 1
Nonconformance Report

IDENTIFICATION

1. Originator Name: 2. Date: 3. NCR No. :

4. Contractor: 5. Location of NCR:

6. Description of non-conformance:

7. Category of non-conformance: 1 2 3 N/A

8. Entered into NCR Tracking Log? [ ] Yes [ ] No

CORRECTIVE/PREVENTIVE ACTION & DISPOSITION

9. Independent verification required? [ ] Yes [ ] No
10. Planned Corrective/Preventive Action (comments):

No. Corrective Action

11. Disposition (if applicable)? [ ] Use as is [ ] Rework [ ] Repair [ ] Reject [ ] Alt. use [ ] Others
12. Person(s) Responsible for the Corrective/Preventive Action 13. Approval of Correction/Preventive
and/or Disposition: Action
No. Name(s) Due Date

Owners’ Engineer

Date

CLOSING THE NON-CONFORMANCE

14. Planned Corrective/Preventive Action Has Been 15. Independent Verification Has Been
Completed: Completed
No. Names Date

Owners’ Engineer

Date
EXHIBIT 2