IX.  DISCREPANT MATERIAL ACTIONS

  1. ROUTINE SCRAP CONTROL
    1. SCRAP CASTING RESULTING FROM HOT INSPECTION PROCEDURES (MISRUNS, NON-FILLS, MOLD RUNOUTS, ETC.) WILL BE IMMEDIATELY PLACED IN THE APPROPRIATE COLOR CODED DRUMS FOR RECYCLING. THE SAME PROCEDURE WILL APPLY TO OBVIOUS SCRAP FOUND OR GENERATED IN THE CUTOFF AND CLEANING AREAS.
    2. DISCREPANT MATERIAL FOUND BY THE QUALITY CONTROL PERSONNEL AFTER CASTINGS HAVE CLEARED THE CLEANING DEPARTMENT WILL BE PROCESSED AS FOLLOWS; MATERIAL ON WHICH THERE IS DOUBT AS TO FINAL ACCEPTABILITY WILL BE REFERRED TO THE MATERIAL REVIEW BOARD HOLDING AREA FOR DISPOSITION BY THE MATERIAL REVIEW BOARD.
  2. MATERIAL REVIEW BOARD PROCEDURES
    1. THE MATERIAL REVIEW BOARD WILL CONSIST OF THREE MEMBERS:
      1. THE QUALITY CONTROL MANAGER OR HIS REPRESENTATIVE
      2. THE MANUFACTURING MANAGER OR HIS REPRESENTATIVE
      3. THE GENERAL MANAGER OR HIS REPRESENTATIVE
    2. THE MATERIAL REVIEW BOARD WILL MEET ON CALL TO REVIEW DISCREPANT MATERIAL SUBMITTED FOR EVALUATION AND DISPOSITION. MATERIAL WILL BE SUBMITTED TO THE MATERIAL REVIEW BOARD FROM TWO SOURCES:
      1. WITHIN THE PLANT
      2. CUSTOMER RETURNS
    3. THE DISPOSITION ACTION OF THE MATERIAL REVIEW BOARD WILL GENERALLY FALL WITHIN ONE OR MORE OF THE FOLLOWING:
      1. SCRAP THE MATERIAL
      2. HAVE THE DISCREPANT CASTINGS REWORKED TO MEET CUSTOMER'S REQUIREMENTS
      3. SUBMIT THE DISCREPANT MATERIAL TO THE CUSTOMER FOR EVALUATION
      4. CUSTOMER RETURNS WILL NORMALLY BE SCRAPED OR REWORKED. IN SOME CASES, THE CUSTOMER MAY REQUEST A RE-EVALUATION FROM THE MATERIAL REVIEW BOARD.
    4. THE MATERIAL REVIEW BOARD WILL USE ALL INFORMATION AVAILABLE IN REACHING ITS DISPOSTION DECISION INCLUDING, IF AVAILABLE , BUT NOT LIMITED TO:
      1. THE ENGINEERING DRAWING
      2. MATERIAL AND INSPECTION SPECIFICATIONS
      3. PAST HISTORY
      4. CUSTOMER COMMENT
    5. THE MATERIAL REVIEW BOARD WILL COMPLETE A MATERIAL REVIEW BOARD ACTION REPORT WITH DISTRIBUTION TO QUALITY DEPARTMENT AND REVIEW WITH MANUFACTURING.
    6. THE MRBAR WILL BE APPROVED BY THE QUALITY CONTROL MANAGER OR HIS AUTHORIZED REPRESENTATIVE AND THE GENERAL MANAGER OR HIS AUTHORIZED REPRESENTATIVE.
  3. CORRECTIVE ACTION PROCEDURES
    1. CORRECTIVE ACTION WILL BE TAKEN ON ANY OF THE FOLLOWING SITUATIONS:
      1. UNACCEPTABLE SCRAP RATE DURING MANUFACTURING
      2. UNACCEPTABLE RETURNED MATERIAL RATE
      3. CORRECTIVE ACTION REQUEST FROM THE CUSTOMER.
    2. EVERY EFFORT WILL BE MADE TO REPLY TO THE CUSTOMER WITHIN TEN (10) DAYS.
    3. IF A FINAL REPORT CAN NOT BE ISSUED WITHIN TEN (10) DAYS, AN INTERIM REPORT WILL BE FORWARDED TO THE CUSTOMER.
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