PIC - T. F. Orlin
FPM - P. B. Hoke
Directives Coordinator
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Date Printed:_________________________ Verifier:__________________________
I. PURPOSE
This procedure identifies the requirements necessary to
establish and implement an inspection program in support of
Lockheed Martin Energy Research, Inc., activities. The inspection
program will identify and verify conformance of items and
services to documented specifications, instructions, procedures,
and drawings; provide for independence of inspection personnel;
and set forth inspector qualification requirements in accordance
with ORNL criteria and appropriate codes.
II. REQUIREMENT REFERENCES
A. DOE Order 5700.6C, Quality Assurance
B. Y/QD-15, "LMES Quality Program Description"
C. X-QA-1, "ORNL Quality Assurance Program"
III. SCOPE/LIMITATIONS
The provisions of this procedure apply to all ORNL
organizations involved in activities where inspection is used to
verify implementation of specified requirements. Inspection is
applicable to critical and complex safety systems and equipment,
safety-class items, permits and vital missions, research and
development, facilities operations, manufacturing, processing
and production, product qualification, and site remediation,
construction, and installation. Inspections shall be performed
for items important to the business success of ORNL.
Inspection planning, in-process, in-service, receipt, reinspection,
source, and final inspections, and specification of acceptance
criteria are further addressed.
IV. DEFINITIONS
A. Complex Item - item with quality characteristics, not wholly
visible in the end item, for which contractual conformance must
be established progressively through precise measurements, tests,
and controls that are applied to the item individually or in
conjunction with other items during purchasing, manufacturing,
assembly, and functional operation.
B. Critical Application - an application in which the failure of the
item could cause personal injury, injure the environment, or
jeopardize security or any vital ORNL mission.
C. Inspection - examination or measurement to verify whether an item
or activity conforms to specified requirements.
D. Inspection Plan - a document identifying frequency of inspection,
characteristics to be inspected, inspection methods, data to be
recorded, and acceptance criteria.
E. Noncomplex Item - item with quality characteristics for which
simple inspection and testing of the end product are sufficient
to determine conformance to contractual requirements.
F. Noncritical Application - any application other than a critical
application.
V. REQUIREMENTS
A. General
1. Organizational responsibilities for inspection shall be
described and documented.
2. Inspection plans or procedures shall be developed with the
assistance of the quality assurance organization, engineering,
or other appropriate organizations, as necessary.
3. Results from final inspections shall be evaluated and
documented, and their level of conformance to specified
requirements shall be determined by responsible management.
4. Inspection practices associated with ORNL activities
shall be periodically audited to ensure proper implementation
and adequacy.
5. Procedures developed to implement the ORNL
inspection program shall provide criteria for determining when
inspections are required and shall define how inspections are
performed.
B. Inspection Planning
1. Inspection activities shall be planned, executed, and
documented in terms of inspection types (e.g., receiving, in-
process, in-service, reinspection, source hardware, process,
or final inspection necessary to verify quality of work
activities).
2. Planning documentation shall identify characteristics,
personnel qualifications, inspection frequency, mandatory hold
points, inspection methods, acceptance criteria, and data to
be recorded and shall provide for recording objective evidence
of inspection results.
3. Inspection plans shall be developed, reviewed, approved, and
issued before initiating inspection activities and shall then
be controlled in accordance with quality records requirements.
4. Criteria shall be provided for determining the accuracy
requirements and calibration status of inspection equipment
and instrumentation.
5. Required tests shall be identified and (as appropriate)
monitored or witnessed with reference to the test procedure.
6. Sampling procedures, when required, shall be made available
to inspection personnel trained in their proper use. If a
sample is used to verify acceptability of a group of items,
the sampling procedure shall be based on recognized standard
practices.
7. Procedural provisions shall be established to prevent work
from proceeding beyond established hold points until it is
reviewed or inspected by a designated individual.
8. Procedural provisions shall be established for indirect
control through monitoring of processing methods, equipment,
and personnel when direct inspection is impossible or
disadvantageous. Both inspection and process monitoring shall
be provided when necessary for adequate control.
9. Combined inspection and process monitoring methods, when used,
shall be performed systematically to ensure that the specified
requirements for control of the process and quality of the
item are achieved throughout the process.
10. Where required, controls shall be established and documented
for the coordination and sequencing of these activities at
established inspection points during successive stages of the
conducted process or construction.
C. Inspection Personnel: organizational provisions shall be made to
ensure that
1. inspection personnel do not report directly to the immediate
supervisors responsible for performing the work being
inspected;
2. each person who verifies conformance of work activities for
the purpose of acceptance is qualified to perform the assigned
inspection task in accordance with ORNL procedure
X-QA-1, "ORNL Quality Assurance Program";
3. inspections by persons receiving on-the-job training are
performed under the direct observation and supervision of a
qualified individual;
NOTE: verification of conformance shall be performed by a
qualified individual until trainees achieve
qualification; and
4. personnel performing inspection activities requiring specific
qualifications such as education, experience, or certification
to codes or standards shall have received appropriate training
and certification. This information shall be documented in
accordance with X-QA-1.
D. Inspection Program Implementation
1. Inspection plans shall be reviewed by the appropriate
organization for each identified inspection activity and shall
include the following, as applicable:
a. referenced drawings, specifications, purchase orders,
process or flow sheets, travelers, or any document
identifying characteristics to be inspected or to be
obtained for use during inspection;
b. inspection frequency or the time of process verification
and related schedule;
c. data to be recorded;
d. identification of the inspection method;
e. identification of quantitative acceptance criteria;
f. identification of mandatory hold points and witnessing by
third parties;
g. consent to waive specified hold points and recording of
consent before continuation of work beyond the designated
hold points;
h. identification of documents to become quality assurance
records;
i. reinspection or retest to verify acceptability following
modifications, repairs, or replacements of items that have
previously received final inspection;
j. required in-service inspection or surveillance of
structures, systems, or components that is planned and
executed by or for the organization responsible for
operation; and
k. development and implementation of inspection methods to
verify that the characteristics of an item remain within
specified limits. Inspection methods shall include
evaluations of performance capability of essential
emergency and safety systems and equipment, verification
of calibration and integrity of instruments and instrument
systems, and verification of maintenance, as appropriate.
2. Records shall include, as a minimum, the following
information:
a. identification of item inspected, examined, or tested
(part number, prototype, production model, or other
information);
b. date of the inspection, examination, or test;
c. equipment used, with identification numbers and
calibration status, as applicable;
d. results or acceptability;
e. signature of inspector, or other identifier such as
stamp number;
f. signature of person(s) evaluating the results;
g. reference to documented procedures or instructions;
h. any separate inspection, evaluation, and technical
documentation (charts, recording, or film); and
i. reference to any deviation or nonconformance reports
generated.
3. Reporting of inspection results shall identify the
following:
a. any inspections made (and documented) at specified hold
points, indicating whether compliance with acceptance
criteria has been achieved; and
b. a review of records for adequacy and completeness,
including records of previous inspections and
nonconformances, before final disposition of each item
or service. The preparation, review, and approval by
authorized personnel of the final inspection report
shall certify that all required acceptance criteria have
been achieved.
Approved by: [J. H. Swanks]
Associate Director
Operations, Environment, Safety, and Health
Oak Ridge National Laboratory
PIC - T. F. Orlin
FPM - P. B. Hoke
Directives Coordinator
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Updated:Wednesday, 12-Feb-97 13:02:26 EST(npn)