# Presentation: 349276

## GPR 5330.1 Product Processing, Inspection and TestTraining Module Rev. C9/11/2006[Work Order Authorization Form 4-30]

-    OPR: Code 500
- Contact:  James Ryan  6-6003

## Product Processing, Inspection and Test

- General
- GPR 5330.1 describes how product processing, including manufacturing, assembly, integration, test, and inspection, should be planned, approved, and documented.
- The GPR introduces the Work Order Authorization Form 4-30 which serves the “**dual purpose**” of “**work authorization**” and “**processing log**” for documenting processing events.

## Product Processing, Inspection and Test

- More about WOA Form 4-30 [Accessed from GDMS Forms Section or On-Line Applications]
- Required to plan and document processing events
- Requires approval prior to work initiation
- Can reference other documentation (e.g., assembly drawings, procedures, test plans, etc.)
- Used to log processing events/details and other relevant information to form a complete history of the build
- Used to record, where required, quality inspection sign-offs
- Used to indicate inspection, processing, and test status
- Is an extremely important Controlled Document
- Becomes a Record to be maintained by the project after final product completion and delivery

## Product Processing, Inspection and Test

- Definitions
- Product Design Lead (PDL):  The manager or leader with overall responsibility for managing the design activity, managing the technical and organizational interfaces identified during design planning, and where required, forming and leading the Product Design team (PDT).
- Final Inspection and Testing:  A verification that the finished product conforms to specified requirements.  The verification assures that all specified inspection and tests, including those specified either on receipt of product or in process, have been carried out and that the results meet specified requirements as required by the quality plan and/or documented procedures.
- In-process Inspection and Testing:  A verification by inspection and/or testing of quality characteristics, defined by project quality requirements or documented procedures, during the processing of a product.

## Product Processing,  Inspection and Test

- Implementation
- How the WOA will be used to support an activity is defined by the project in the project plan or other comparable project documentation.  This definition includes the approval structure to be employed, how WOAs will be numbered, and how changes to WOAs will be managed/approved.  The level of detail on the WOA should be commensurate with the complexity of the task at hand and the acceptable level of risk for the given project.
- Minimum requirements include:
- Must start using WOAs at the start of the manufacturing phase or in the case of software development, when the initiative comes under configuration control.
- Must use WOAs to address in-process and final inspection and test events including all functional and environmental tests required for product validation.  When such tests are used to verify design, WOAs are also to be used.

## Product Processing,  Inspection and Test

- Implementation cont.
- The Product Design Lead (PDL) uses the WOA to guide the development of the product and to ensure product quality.
- All required approvals shall be obtained on the WOA form prior to the start of work.
- All WOA pages shall be numbered, and events should be numbered to coincide with the chronological flow of the work.  When numbering events, consideration should be given to adding intermediate events to capture more detail. This will allow easier reconstruction of the work flow.  For instance,
- blank lines could be left on the WOA form between events numbered 10,20,30, etc., to leave additional numbers/space for adding intermediate processing steps after initial approval of the WOA,
- or additional steps could be added after event 7 and before event 8 by numbering events 7A, 7B, 7C, and so on.

## Product Processing,  Inspection and Test

- Implementation cont.
- The PDL is responsible for determining and documenting the work (typically recorded by technicians doing the work), including inspections (typically performed and recorded by Q.A. personnel) and tests, to be conducted on the product.  Any special items or equipment needed for the inspections or  tests shall be identified.
- Level of detail used for planning product processing is as required by the Project and the PDL and should match the need:
- Critical tasks performed by fairly new people may well  require more detail on the WOA or perhaps the generation of a specific Work Instruction to be referenced on the WOA.
- Routine tasks performed by seasoned experts would require less.
- The approved WOA should reflect the necessary steps that have been determined will ensure product quality.  Continuation WOA sheets can be used to capture additional relevant details of the processing.  Add existing WOA # and sequential page # to each continuation sheet added.  This is the “Cert Log” mode of using the WOA.

## Product Processing Inspection and Test

- Specific Instructions** **
- The responsible work performer or inspector shall:
- Verify completion of previous work, inspections, and tests.  Ensure that the product is ready for the next processing step, or, if previous work has not been completed, that continued processing is approved.  PDL or other responsible person should write on the WOA “OK to Proceed” and their initials/date.
- Verify appropriate documentation is available and current.  To reduce possible ambiguity in the reconstruction of events, all documentation referenced should provide the “revision status”  of the documentation “being used.”  Do not simply state “current revision, or latest revision.”    Examples include:
- Drawing GD 1234567 Rev. B or Rev. - (if no revisions have been made)
- Vibration Test Plan ABC-12345-67 Rev. C.

## Product Processing Inspection and Test

- Specific Instructions** **cont’d
- Ensure the required Handling Equipment and Inspection, Measurement, and Test Equipment (IMTE) is available, in-date, and tagged appropriately.
- Record all IMTE Equipment Control Numbers (ECNs) and/or Manufacturer’s Serial Numbers on the WOA or attached/referenced procedures.  This is very important because it provides traceability should a subsequent calibration of the IMTE used determine that it is “out-of-tolerance.”
- Perform the specified work and associated inspections and tests identified on the WOA and document work events.
- Obtain all required approvals at the appropriate steps throughout the processing of the product.  An entry should be made beside each event in all “Performed by” and “Inspected by” blocks on the WOA, even if this entry is “N/A” or “/.”  This should be done prior to proceeding to the next processing event.  “N/A” or “/” can only be used in the “Performed by” field for an “inspection event only.”

## Product Processing Inspection and Test

- Specific Instructions** **cont’d
- When product is found to be nonconforming, process in accordance with  GPR 5340.2 Control of Nonconformances.
- Ensure all Problem Reports/Problem Failure Reports (PR/PFRs) and Nonconformance Reports (NCRs) that might impact the continued processing of the product are properly dispositioned.  If, after the generation of a PR/PFR or an NCR, it has been determined that there will be no impact to continued processing, the PDL or another responsible person should indicate this on the WOA.  For instance, record on the WOA “OK to Proceed” or  “OK to proceed to Event # 80,” or “Skip events 70-110 and initiate further processing at Event # 120.”  Initial and date the note.

## Product Processing, Inspection and Test

- Specific Instructions cont’d
- Upon satisfactory completion of all planned work, and inspection and tests, the PDL (and possibly Q.A.) shall verify and document on the WOA that all planned activities have been satisfactorily completed, that nonconforming product has been properly dispositioned, and that all pertinent documentation is complete and available.  The final page number of the WOA shall be recorded on the final page (and preferably on all WOA pages) to indicate the complete WOA.  Example: Pg 10 of “10.”
- WOAs are very important controlled documents.  Responsibility for their management proceeds from PDL to PDL as the product moves to higher levels of development and, finally, to the Project when the product is completed and delivered.

## Product Processing,  Inspection and Test

- Special Note for Software Developers
- Software developers may find the WOA inappropriate for their work and may use an equivalent form or process.  The Information Systems Center (ISC) Product Development Handbook (580-PG-8730.3.1) provides an acceptable alternative.