1、DEPARTMENTS OF THE AIR FORCE, THE ARMY THE NAW THE DEFENSE LOGISTICS AGENCY Washington DC 20330-5000 Quality and Reliability Assurance AFR 7418 SECNAVINST 4855.8 DUR 8200.1 1 14 July 1989 AR 702-17 QUALITY IMPROVEMENT AND PRODUCT NONCONFORMANCE REDUCTION This regulation implements DOD policy on nonc
2、onformance reduction and Federal Acquisition Regulation (FAR) Parts 46 and 52 policy on nonconforming material. It establishes policy and requirements to address improving quality through reduction in the cost and incidence of nonconforming products. It complements Total Quality Management (TQM) pol
3、icy on nonconformance prevention which focuses on those actions that should be taken early in the design, development and production of new systems,subsystems, or equip- ment to achieve first-pass conformance and prevent repetitive nonconformances throughout the produc- tion process. This regulation
4、 applies to all DOD Contracting Mices (COS) and Contract Administration Offices (CAOs); however, CAOs will not initiate or continue action under paragraphs 5 or 6 whena contrac- tor has demonstrated satisfactory evidence of continuous process improvement and is achieving low levels of nonconformance
5、. 1. Background: a. It is Government policy to reject material and supplies not conforming in all respects to contract requirements (FAR 46.407). (1) Deviation from this policy is permissi- ble only as authorized in FAR 46.407, when ac- ceptance of such material and supplies is in the best interest
6、of the Government. (2) The act of offering nonconforming ma- terial to the Government by a contractor should be an exception. (3) The consistent offering of nonconform- ances is usually an indication of inadequate con- trol over quality or over specuication of techni- cal requirements. b. CAOs may r
7、eject or accept minor waivers for nonconformances unless authority is with- held by the CO. Federal Acquisition Regulation (FAR) Parts 46 and 52 describe conditions un- der which a contract will be modified to provide an equitable price reduction or other consider- ation when supplies or services in
8、volving minor nonconformance are accepted. c. This regulation harmonizes CAO ap- proaches and assists the Administrative Con- tracting Officer (ACO) in determining appropri- ateness of an equitable price reduction or other e consideration for minor nonconformance. The purposes of seeking considerati
9、on are: (1) The Government has a legal right to the products pecified in the contract. (2) Acceptance of nonconformance can re- lieve financial incentives for improvement and incorrectly communicate to a contractors man- agement and workforce that it is acceptable to produce nonconforming material.
10、(3) Consideration serves to focus manage- ment attention on the cost and consequences of reprocessing or replacing nonconforming mate- rial. d. Contracting Offices are encouraged to: (1) Require contractors to disclose costs as- sociated with the correction and dispositioning of nonconforming materi
11、al. (2) Consider these costs in determining the effectiveness of potential contractors proposed quality programs. Negotiations should reflect improvement in quality performance and re- duction in historical levels of nonconformance costs. (3) Consider contractual incentives for con- tractor quality
12、improvement and nonconform- ance cost reduction beyond that baselined in the negotiated price. No. of Printed Pages: 6 OPR: SAF/AQCM (R. G. Bradley) Approved by: Brig Gen J. D. Slinkard Writer-Editor: L. J. Mazulewicz Distribution: See Page 4 rn 3535789 0554b73 954 rn Provided by IHSNot for ResaleNo
13、 reproduction or networking permitted without license from IHS-,-,-a AFR 74-WAR 72-17ISECNAVINST 4866.#DLAR 8200.11 14 July 1989 (4) Support nonconformance reduction ef- forts by CAOS on existing production contracts. !& Objectives. The objectives of this regula- tion are to reduce or eliminate nonc
14、onforman- ces and promote continuous quality improvement. Continuous quality improve- ment is intended to address sigdicant cost dri- ver$ that prevent full conformance to contract requirements. Continuous quality improve- ment involves appropriate action to: a. Establish goals and practices to impr
15、ove manufacturing process capability. b. Minimize process variability and increase c. Reduce deficiencies during manufactur- d. Correct unrealistic requirements. e. Improve first-pass acceptance rates. f. Reduce cost associated with scrap, rework andrepair. g. Address other criteria and controls tha
16、t can increase productivity, manufacturing or operational efficiency and product utility. product uniformity. ing, test and inspection. 3. Scope. This regulation applies to fmed- price type production contracts with higher-lev- el contract quality requirements as defined by FAR 46.202-3. It applies
17、to contracts at prime contractor facilities, material from offsite feed- er locations, inter-organizational transfers, and subcontracted or supplier items on which mate- rial review is pedormed by the prime contrac- tor. It may also be applied to other contracts, such as those with incentive or awar
18、d provi- sions, that are appropriate for quality improve- ment. a. This regulation applies to minor waivers and deviations processed by CAOS with author- ity to approve or concur in classification of class II engineering changes unless otherwise direcb edbytheC0. b. ContniCtingfices andCAOs will enc
19、our- age prime contractors to implement a noncon- forming material reduction program meeting the same objectives with their major/critical subcontractors and suppliers. 4, Policy: a. The CAO will evaluate a contractors prod- uct nonconformance history as: (1) Evidence of the effectiveness of a con-
20、tnictors engineering, manufacturing, quality asaurance or inspection4 systems to amm- plish their objectives. (2) A measure of the effectiveness of correc- tive action efforts. (3) A condition for accepting minor noncon- formances submitted by the contractor. b. The CAO will ensure efforts under thi
21、s regulation to address continuous process im- provement and product nonconformance reduc- tion are compatible with contract administra- tion delegations and contract requirements. On prime contracts for major defense acquisition programs the CAO will coordinate with the CO when an agreement with th
22、e contractor is planned to address quality improvement for nonconformance reduction. In the event of dis- agreement between the CAO and the CO, the disagreement will be elevated to higher man- agement as necessary to achieve resolution. c. The CAO will not initiate or continue ac- tion under paragra
23、phs 5 or 6 of this regulation for a facility or process for which a contractor has demonstrated to the CAO satisfactory evi- dence of continuous process improvement and is achieving a low level of nonconformance. CAO action related to obtaining consideration and quality improvement for product nonco
24、nform- ance reduction will be suspended selectively or collectively within a contractor facility when the CAO determines: (1) The cost to the Government of process- ing a contract modification will exceed the cost to a contractor in correcting the nonconform- ance or replacing the product with one f
25、ully con- (2) Opportunities for improvement no long- (3) Continuation is otherwise no longer in forming. er merit CAOattention. the Governments interest. 6. Procedures for Nonconformance Reuc- tion (Case-by-Case Methods): a. The CAO will determine what nonconfor- mance level (quantity or monetary th
26、reshold) is reasonable for specific contractor products or fa- cilities as a basis for seeking consideration on nonconforming material. The intent is not to condone some level of contractor deficiency, but to determine where limited Government and contractor resources can be used most effective- 1Y.
27、 b. The ACO, quality assurance personnel and other representatives as determined by the AC0 (such as price analysts or engineers) will jointly establish monetary, quantity or other thresholds for a contractors products. = 3515789 0554b74 890 = Provided by IHSNot for ResaleNo reproduction or networki
28、ng permitted without license from IHS-,-,-AFR 74-1WAR 70217/SECNAVINST 4865.WDLAR 820.11 14 July 1989 a (1) A threshold must be discussed with the contractor,but the AC0 has ultimate decision authority on an appropriate level and when to seek consideration. (2) A monetary threshold may be based upon
29、 the cost to replace the product with a fully conforming item or other basis as determined by the ACO. Replacement cost includes labor, ma- terial and overhead costs expended in producing the item prior to submittal for material review. c. When the CAO determines action is war- ranted for a nonconfo
30、rmance minor waiver (re- pair, standard repair, or-use-as-is material re- view disposition) or minor deviation accepted by the Government, the AC0 will review the fol- lowing as factors in determining an equitable price reduction or other consideration due to the Government: (1) Government expense f
31、or, reinspection, retest and the administrative cost of processing a contract modification. (2) Savings to the contractor in fabricating material with the nonconformance. (3) Expense avoided if the contractor is not required to: (a) Replace the product with one fully conforming. (b) Reprocess the pr
32、oduct. These costs avoided include material, labor, and overhead related to repair. (c) Reinspect and retest. These costs avoided include disassembly and repair. d. The AC0 will determine an appropriate approach in accordance with the contract for ob- taining consideration such as: (1) A price reduc
33、tion implemented through a separate contract modification to the appro- priate contract. (2) Accumulating a number of actions be- fore executing a contract modification. (3) Including consideration for nonconfor- mance when a contract is being modified for other reasons, rather than preparing separa
34、te moduication. 6. Joint Contractor and CAO Quality Im- provement Agreement Procedures: a. When the size of the contractor facility, complexity of the contractor organization, or the number of products and nonconformances warrant an approach to minimize the adminis- trative work load on the contract
35、or and Govern- ment, a joint contractor and CAO agreement on quality improvement for nonconformance re- duction is- mutually beneficial. Such agree- e ments are not precluded with smaller contrac- tors. b. The agreement will be tailored to a specmc contractor facility or process and designed to fa-
36、tus on elimination of significant causes of non- conformance. c. if such an agreement is warranted urider paragraph 4, but cannot be negotiated, the CAO will use case-by-case procedures at paragraph 5. d. Joint contractor and CAO quality im- provement agreements will include: (1) A Product Assurance
37、 Council (PAC) or similar joint group composed of top level mdn- agement from the contractor and CAO. The PAC serves as a senior focal point to integrdCC product integrity, quality, engineering, manu- facturing, and purchasing actions, and to iden- tify and prioritize projects and resources neces- s
38、ary to implement effective action that achieves quality improvement. (2) Management commitment to establish priorities and goals. (3) Improvement goals for nonconforming material reduction. Goals to be tracked and ad- dressed as part of the agreement may incl* nonconformances dispositioned as minor
39、walv- ers (repair, standard repairs, use-as-is material review dispositions), minor deviations, rework, scrap, return-to-supplier or other agreed to goals that affect overall nonconformance rates. (4) Measurement indicators to provide management visibility of performance against goals. (fi) The amou
40、nt and method of obtaining consideration when improvement goals for mi. nor waivers or deviations have not been met. Positive incentives may also be considered fd contractors who perform better than estab lished goals. e. The PAC may also serve multiple func- tions as a Corrective Action Board (CAB)
41、 when MIL-STD-1520, Corrective Action and Disposi- tion of Nonconforming Material, is on con- tract,or as a Quality and Productivity Improv- ment Program Advisory Board. f. Improvement goals should reflect the maturity of a program, past and current pedo?- mance, and contractor work load volume. Mea
42、- surement indicators, performance goals,consideration, positive incentive and ad- ministrative aspects should complement co- tractor-initiated quality improvement and be basedon existingdata systems. 3515789 0554b75 727 Provided by IHSNot for ResaleNo reproduction or networking permitted without li
43、cense from IHS-,-,-4 AFR 74-1WAR 70%17/SECNAVINST 4865.8/DLAR 8200.11 14 July 1989 g. Agreements may include contingencies for situations such as strikes, plant shutdowns and unanticipated work loads. The data should be normalized as necessary to anticipate sign& cant changes. h. Consideration will
44、be obtained when im- provement goals identified in the agreement for minor waivers or deviations have not been met. Consideration will be provided to the Govern- ment, as determined by the AC0 (see paragraph 5c) and stipulated in the agreement. i. With CO concurrence, agreements may address monetary
45、 adjustments of award fees based on quality improvement goals and perfor- mance. BY ORDER OF THE SECRETARIES OF THE AIR FORCE, THE ARMY, THE NAVY AND THE DIRECTOR, DEFENSE LOGISTICS AGENCY: OFFICIAL WILLIAM O. NATIONS, Colonel, USAF Director of Information Management and Administration OFFICIAL MILT
46、ON H. HAMILTON Administrative Assistant to the Secretary of the Army OFFICIAL BY ORDER OF THE DIRECTOR LARRY D. WELCH, General, USAF Chief of Staff CARL E. VUONO,General, United States Army Chief of Staff W. J. WILLOUGHBY, JR., Director Reliability, Maintainability and Quality Assurance Mice of the
47、Assistant Secretary of the Navy (Shipbuilding and Logistics) JAMES J. SINGSANK, Colonel, USA Staff Director, Administration Defense Logistics Agency DISTRIBUTION: Air Force: F Army: Distribution of this publication is made IAW the requirements on DA Form 12-09-E, block 5013, intended for command lev
48、el D for Active Army, USAR and ARNG. Navy: SNDL Al A3 (CHIEF OF NAVAL OPERATIONS) C4L (DIRECTOR OF NAVAL LABORATORIES) C79 (DIRSSP SHORE BASED DETACHMENTS) C80 (COMNAVMRSYSCOM SHORE BASED DETACHEMENTS) C81 (IMMEDIATE OFFICE OF THE SECRETARY) (ASSTSECNAV(S&L) RM&QA ONLY) (10 CYS) (COMSPAWARSYSCOM SHO
49、RE BASED DETACHMENTS) (5 CYS EA) 3535789 0554676 663 Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-AFR 74-18/AR 70%17/SECNAVINST 4866.WDLAR 8200.1 1 14 July 1989 5 C82 (COMNAVFACENGCOM SHORE BASED DETACHMENTS) (5 CYS EA) (LESS NAVAL FACILITIES ENGINEERING COMMAND DETACHMENT, REINDEER STATION) (NAVAL SUPPLY CENTER DETACHMENTS) (5 CYS EA) (NAVAL REGIONAL CONTRACTINGCENTER DETACHMENTS (10 CYS EA) (COMNAVSEASYSCOM SHORE BASED DETACHMENTS) (10 CYS EA)
