3rd Party Operations & Containment Management

SERVICE DETAILS

Here are the detailed explanations for the services provided by Modulus Metal for 3rd Party Operations & Containment Management:

Sorting

Sorting involves the systematic inspection of components or products to segregate conforming parts from non-conforming ones. Inspectors thoroughly check each item for defects, such as surface damage, dimensional inaccuracies, or material inconsistencies. Sorting can be manual or automated, depending on the complexity and volume of products. After inspection, parts are categorized into “acceptable,” “repairable,” or “reject” categories. The process helps prevent defective products from reaching subsequent production stages or the end customer.

Key Steps:

1. Pre-inspection Preparation: Understanding customer specifications and sorting criteria.
2. Visual/Dimensional Inspection: Identifying defects like surface irregularities or incorrect dimensions.
3. Segregation: Sorting conforming and non-conforming products based on the set criteria.
4. Documentation: Recording the results for customer reporting.
5. Handling Defective Parts: Deciding whether to rework, scrap, or return defective items based on customer instructions.

Reworking

Reworking is the process of correcting defects or modifying non-conforming parts to meet quality standards without scrapping the product entirely. Reworking may involve re-machining, adjusting dimensions, surface treatment, or replacing faulty components. Reworking ensures that salvageable products are brought back into compliance with required specifications. It requires a deep understanding of both the product and the defects to ensure effective correction without compromising performance.

Key Steps:

1. Defect Identification: Pinpointing the cause and type of defect.
2. Corrective Action: Implementing corrective measures, such as machining, welding, or polishing.
3. Quality Assurance: Re-inspecting the reworked part to ensure it meets original specifications.
4. Documentation: Tracking all rework activities to maintain accountability and compliance with standards.
5. Approval for Use: Ensuring that the reworked part is certified for use by a qualified inspector or quality manager.

Controlled Shipping Levels (CSL)

• CSL 1: This is the first level of controlled shipping, where the supplier is responsible for containing non-conforming products before they are shipped to the customer. The supplier implements internal corrective measures, including additional inspections at their facility to ensure that no defective parts are delivered. CSL 1 ensures that non-conformities are caught at the source, and only compliant products leave the supplier’s facility.

Key Steps:

1. Internal Corrective Actions: Implementing extra layers of inspection before shipping.
2. Supplier Responsibility: Supplier conducts additional inspections independently.
3. Monitoring: Ensuring that all outgoing shipments meet customer specifications.
4. Reporting: Regular feedback is provided to the customer on the status of corrective actions.

• CSL 2: In CSL 2, a third-party inspection team is added to the process. In addition to the supplier’s internal containment measures, an independent inspector verifies the quality of the products before they are shipped. This process adds an additional layer of control, ensuring that products meet quality standards and are free from defects.

Key Steps:

1. Third-Party Verification: External inspectors check parts for compliance.
2. Double Layer of Inspection: Both supplier and third-party inspectors ensure no defects.
3. Enhanced Reporting: Detailed reports are provided to both the supplier and the customer.
4. Supplier-Inspector Collaboration: Ensuring continuous improvement in defect detection.

• CSL 3: CSL 3 is the most stringent level of containment, involving the highest level of oversight. Both the supplier and customer may require a third-party inspector to be stationed full-time at the supplier’s facility. These inspectors closely monitor the production process, perform audits, and verify that all quality standards are strictly followed. CSL 3 is used in situations where critical defects could have severe safety or performance implications, and where the customer demands absolute assurance of quality.

Key Steps:

1. Full-Time Third-Party Presence: An inspector is on-site to supervise the production process.
2. Continuous Audits: Regular audits of both the manufacturing process and quality systems.
3. Detailed Reporting and Communication: Real-time communication of issues with the customer.
4. Zero-Defect Strategy: Aiming for 100% defect-free products with proactive defect management.

Firewalls and Exit Management

Firewalls refer to establishing specific control points within the production or supply chain to catch defects before they progress further down the line. These firewalls act as checkpoints, where products are quarantined and inspected before moving forward. Exit management ensures that products exiting the supplier’s facility or containment area meet all quality standards before they are delivered to the customer. The process may involve multiple inspection stations and collaboration between suppliers, inspectors, and customers.

Key Steps:

1. Setting Control Points: Establishing checkpoints within the process to catch defects early.
2. Quarantine Areas: Holding defective parts for rework or rejection.
3. Final Inspection: Ensuring that all parts leaving the facility meet customer standards.
4. Collaborative Review: Ensuring proper communication and approval between stakeholders.

Containment Services and On-Site Inspections

Containment services ensure that defective products are isolated from the production line or supply chain to prevent further progression or shipment to the customer. On-site inspections involve sending inspectors to the supplier’s facility to conduct real-time audits, sorting, and inspections. The goal is to provide immediate feedback and solutions to quality issues, preventing defective products from reaching the customer and ensuring the supply chain remains uncompromised.

Key Steps:

1. On-Site Presence: Deploying inspectors directly to the supplier’s location.
2. Real-Time Inspections: Conducting on-the-spot inspections to identify and isolate defects.
3. Immediate Feedback: Providing instant reports and corrective actions to the supplier.
4. Defect Containment: Ensuring that defective products are quarantined or reworked before proceeding further in the production process.

These services ensure comprehensive quality management and containment solutions, allowing companies to manage risks, improve supplier performance, and maintain high standards in the final delivery of products.