LRQA Audit Report
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LRQA Audit Report

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Surveillance # 2 Report for: VSE Corporation LRQA reference: UQA 0111079/ 0109 Assessment dates: 20-23 Jan 2009 Assessment location: Alexandria, VA; Ladysmith, VA and Chesapeake, VA Assessment criteria: ISO 9001:2000 Assessment team: Robert Armstrong LRQA office: Houston Contents 1. Executive report ........................................................................................................ 3 2. Assessment summary ............................................................................................... 4 3. Assessment Findings Log - ISO 9001:2000 ............................................................ 18 4. Assessment schedule ............................................................................................. 22 5. Continual improvement tracking log ([ISO9001:2000], [Alexandria, VA.]) ............... 24 6. Visit theme selection ............................................................................................... 26 7. Continual improvement tracking log (ISO 9001:2000, Chula Vista, CA) ............ Error! Bookmark not defined. 8. Certificate details ..................................................................................................... 27 9. Multi-site certificate schedule .................................................................................. 28 Attachments This report was presented to and accepted by: Name: Bob Rouzer Job title: Director of ...

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Surveillance # 2
Report for:
VSE Corporation
LRQA reference: Assessment dates: Assessment location: Assessment criteria: Assessment team: LRQA office:
UQA 0111079/ 0109 20-23 Jan 2009 Alexandria, VA; Ladysmith, VA and Chesapeake, VA ISO 9001:2000 Robert Armstrong  Houston
 
  
    Contents  1. Executive report ........................................................................................................3 2. Assessment summary ...............................................................................................4 3.  ............................................................18Assessment Findings Log - ISO 9001:2000 4. Assessment schedule .............................................................................................22 5. Continual improvement tracking log ([ISO9001:2000], [Alexandria, VA.]) ...............24 6. Visit theme selection ...............................................................................................26 7. Continual improvement tracking log (ISO 9001:2000, Chula Vista, CA)............Error! Bookmark not defined. 8. Certificate details.....................................................................................................27 9. Multi-site certificate schedule ..................................................................................28    Attachments   
This report was presented to and accepted by: Name: Bob Rouzer Job title: Director of Quality
Lloyd's Register Quality Assurance Limited, its affiliates and subsidiaries and their respective officers, employees or agents are, individually and collectively, referred to in this clause as "LRQA". LRQA assumes no responsibility and shall not be liable to any person for any loss, damage or expense caused by reliance on the information or advice in this document or howsoever provided, unless that person has signed a contract with the relevant LRQA entity for the provision of this information or advice and in that case any responsibility or liability is exclusively on the terms and conditions set out in that contract.  Form: MSBSF43000/1.1 - 0506 Report: UQA0111079/0109 - 26-Jan-09 Page 2 of 28
  
     
1. Executive report Assessment outcome: The theme for this surveillance visit was to review purchasing at all applicable sites as well as corporate controls applied by Alexandria.  Summary of assessment: One Open Minor Non Conformity Six New Minor Non Conformities Four Requires Correction Two issues for LRQA follow up  No major findings were observed and therefore VSE Corporation is recommended for continuing certification to the ISO9001:2000 standard.  The Coast Guard division is now incorporated in BAV and has been removed from the LRQA certificate. A revised certificate is attached reflecting this change along with corrections from the previous issue.  The theme for the next visit will be project planning which is an important part of VSE business and has already been addressed as an area for improvement by VSE and is identified as a minor non conformity by LRQA. An issue with the use of the LRQA Logo was observed on the website but VSE have agreed to correct the issue and reference the other certifications b re istrars other than LRQA. System effectiveness and continual improvement: The system at VSE was observed to be effective to deliver customer satisfaction and internal quality driven objectives. Improvements were identified with the use of the Puridiom software which is providing a better reporting system for purchasing.  Primary objectives are generally on target other than contract review CP No 2 and QMS CP No 7which are behind the targets and are being reviewed for action at the management review.  The internal audit process is now performed using the latest Q-Pulse module although more effective reference to findings is necessary in the checklists along with timely action on corrective actions noted. Areas for management attention: No major areas of concern were identified during this surveillance visit however the following areas require management attention   Plans – reviewing the process for  Projectgenerating plans to ensure that the plans provide value to the project and an introduction and explanation of project requirements.  Corrective Actions – ensuring that the Q-Pulse process leads to timely documentation and closure of issues.
 Form: MSBSF43000/1.1 - 0506
Report: UQA0111079/0109 - 26-Jan-09
Page 3 of 28
     
 2. Assessment summary Introduction: A four day surveillance visit was performed at VSE in the Alexandria HQ and Chesapeake and Ladysmith sites. The opening meeting confirmed the scope, theme and method of reporting. The visit commenced with an opening meeting at each site which was attended by local site management and concluded with a closing meeting in HQ attended by the CEO and other members of the senior management team.  Assessor:Day One 20 2009. Chesapeake VA. Robert Armstrong  
 Form: MSBSF43000/1.1 - 0506
Report: UQA0111079/0109 - 26-Jan-09
Page 4 of 28
      Assessment of: ChesapeakeAuditee(s):Al Malubag QMS Manager Project Management QA Audit trails and sources of evidence: Projects Reviewed: USS Kearsarge SPN 35; USS Wasp; Ki LLC PO K08-001467. Procedure – QMP-106, Procedure Tecnico F056319; QA Workbook Internal Audits: Purchasing, HR CAR- 00322 & 320, 323. Evaluation and conclusions: Project Management Project USS Kearsarge A project management book has been developed with the project consisting of Project Plan; Quality Plan; Delivery Order; PO; Check off list. QA Work book In addition to the PM workbook a workbook is developed with relevant documentation including: SOW; QA Manual, PCP, POC & Qualifications, Test & Inspection plan VSE & Technico; AIT work.  Minor NC 0901RAB01 It was observed that the customer requirements as detailed in the DO & SOW have not been converted over into requirements of the Quality Plan and the Project plan and do not always reference customer specification requirements such as MIL E 17555 and MIL STD 2042. The current plans in use are very generic and use information that is standard for all projects but fail to provide a detailed plan for the execution of the unique project in question.  Quality Assurance Inspection VSE was a subcontractor to Ki LLC and work was performed against the contract using Test and Inspection Plans and T & I support records. Internal Audits An audit plan is available detailing audits for 2008 in the Chesapeake and Chula Vista facilities Audits have been performed and recorded in Q-Pulse with corrective actions issued as appropriate. Findings are issued as corrective actions and follow the module in Q-pulse. Documentation Procedures are available for the activities in Chesapeake as required by customer. Quality Records Matrix A quality records matrix is available unique to SELD Chesapeake. Customer Satisfaction Evidence was seen on the system of customer satisfaction surveys as requested by Fleet Maintenance division. The feed back was generally positive although for the second survey it appears that VSE were graded with other suppliers which may not have been a true reflection of the unique performance of VSE. Complaints No complaints are noted for Fleet Chesapeake. Quality Records A quality Matrix is maintained QMF 048 detailing record and retention requirements. Sample of records reviewed as er matrix.   
 Form: MSBSF43000/1.1 - 0506
Report: UQA0111079/0109 - 26-Jan-09
Page 5 of 28
 Plan Assessment of: ning
Audit trails and sources of evidence: AWR OPNAV 4790/2R Procedure FMI-011 Rev 3
     Auditee(s):Steve Mahaffey
Evaluation and conclusions: Planning Process involves receiving an AWR and APL which is assigned to planner. The planner develops a work item which is reviewed and approved. Work is checked using FMF-01 and 56 by the planner and QC. Minor NC 0901RAB02 It was observed that for USS Cole work item 139-11-001 the job has been approved but there appeared to discrepancies between the planner and QC of applicable items. e.g. CFM Material requirements list items 14-16 signed by planning but not by QC also work spec various items on the checklist signed in section 3 by planning but NA by QC. This was also observed on 165-11-001 and 243-11-002  Assessment of: ng CalibReceiviitar noAuditee(s):Bert Caboteja
Audit trails and sources of evidence: PO F054949, F54956, F56272 QMF 28 Inspection Tag Receiving Inspection report 7143 Inspection Level 1 Procedure – QMP115 Calibrated E ui ment- QC004 & 6 Evaluation and conclusions: Receiving Goods are received against the PO and suppliers packing list and the receiving personnel complete to QC9 to indicate inspection. The inspection level is defined on the PO and completed on the QC9E. Any rejects are recorded on the inspection report for action a QC9 is used for Level 1 inspection.  Calibration A list is maintained of active and inactive equipment A gage detail report is maintained with the frequency and next due date and an external certificate is maintained with traceability to NIST.  Assessment of: BAV WarehouseAuditee(s):Luis Gomez
Audit trails and sources of evidence: 8022-e005 eg 8014 Foreign military Sales Database Operations and Maintenance Manual v2.
Evaluation and conclusions: BAV Logistics/Warehouse Material is received through QC9 and material is issued through TCN which issues a shipping manifest for the job. The material when packed is via a shipping manifest and commercial invoices.  
 Form: MSBSF43000/1.1 - 0506 Report: UQA0111079/0109 - 26-Jan-09
Page 6 of 28
 HR Assessment of: 
Audit trails and sources of evidence: Mike Dorr
     Auditee(s):Brenda Bennett
Evaluation and conclusions: HR Records are maintained in cost point database which indicates training given XLRQA 0901RAB03 The use of a costpoint database for training was observed but it not the responsibility of the local training manager to monitor the updating of certifications and minimum mandatory training. This will require follow u at the next LRQA surveillance of Trainin in HQ.  Assessment of: PurchasingAuditee(s):Tom Stein
Audit trails and sources of evidence: PO- F056318, F56178, F054948, F054924 Approved suppliers- Life cycle, Todd Marine Preferred, CDW-G Unrated
Evaluation and conclusions: Purchasing A PUR 1 is issued as a requisition and is approved according to defined limits of authority letter which defines fiscal limits. Where applicable a detail sheet defines extra requirements. A checklist PUR 28 is completed with all the requirements depending on contract value. The PO is generated from the PUR 1 and contains all the details of the contract along with a sub contract agreement. Orders under 10000 are required to have CTO documented on the PO to indicate order has been verbally communicated to supplier- The PO also has a statement on latest issue of specifications. RC0901RAB04 As a one off observation it was noted that PO F054948 does not reference MIL-C-24643.  Supplier Performance Evaluation A PUR 126 is com leted for new su liers indicatin erformance on contract.   Assessment of: ContractsAuditee(s):Sherwin Turner
Audit trails and sources of evidence: DO F0700.0004.A DO F0057.0005
Evaluation and conclusions: Contracts A DO is issued against the main contract and is reviewed using the CA25-2 form and is signed to indicate evidence of review against the award. For contracts a CA25 form is completed with the review including, delivery, SOW and applicable specifications.     Form: MSBSF43000/1.1 - 0506 Report: UQA0111079/0109 - 26-Jan-09
Page 7 of 28
       Assessor:Two 21 Jan 2009 Ladysmith VADay Robert Armstrong  Aud Assessment of:  singnnniPalcrah guPitee(s): Fen Ron axrfaiainahtaNsniboR l Audit trails and sources of evidence: Blanket Purchase Order Roys Electric Motor Services, Sherwin Williams- Blanket PO G054176 Fax 14 Jan 2009 Evaluation and conclusions: Purchasing Stock items A blanket PO is available for materials considered as consumables which are requested from the supplier via phone. Minor NC 0901RAB05 It was noted that a Blanket order system was used for purchasing of repetitive raw materials. The system of releasing orders against the blanket order is not described to allow adequate review and inspection at receiving and monitor supplier conformance to requirements.  Mandatory Material The requirements for mandatory purchasing and this is fed to government sourcing to procure the item. Additional Work Effort (AWE)  Planning Corporate inform Ladysmith of production requirements which is converted over to the production report. Priorities are identified on the weekly production status report with an indication of the current priority for production. The progress towards production targets is monitored against targets with a status defined in a colour code reen and red.  
 Form: MSBSF43000/1.1 - 0506
Report: UQA0111079/0109 - 26-Jan-09
Page 8 of 28
      Keith Wight Assessment of: Paint & MaintenanceAuditee(s):Deandre Morris Sean Ryan White Aaron Monford
Audit trails and sources of evidence: ATLAS 10K Grader 130g ELD 1470 ELF 171 Rev 1.0 Paint Blast request ELI 229 Rev 1.0, ELI 210-rev 8 *C ELD 1084 11/08-11/09; ELD 10343/08-3/09, *c 306 2/08-2/09 Torque wrench, pressure 312 2/08-2/09, 1069 3/08-3/09, tachometer6/08-6/09eld 1020, ELD 1019 6/08-6/09 MWO 9-2330-272-35-1 Vehicle 31/02755 Evaluation and conclusions: Atlas 10K Breakdown Work commences with an initial evaluation of the received vehicle and completion of the technical inspection RC 0901RAB06 The Serial number was not recorded for unit 1577 even though this was an initial checklist requirement.  Grader 130 G Minor NC0901RAB07 It was observed that the oil sample taken on breakdown indicated that sample passed but review of the results indicated a problem with samples that is not identified as additional work effort or follow-up through a further “in process” check. Unit 1397 the paperwork for oil sample is identified as pass but the results are not available in the file indicating analysis.  Wash As per SSPC SP-1 with hand sanding as per paint blast request. Blast Blast is performed per paint blast request with specification defined SSPC SP6. The criterion for blasting is defined in the ELD Blast Guide. Paint The paint is mixed as per manufacturer’s recommendations with mixing ratio defined on instruction sheets in mixing area. The paint follows a defined sequence including Pre-wash- Primer-Topcoat. The lot and expiration date are recorded and the time is recorded to ensure paint is within pot life. DFT checks are performed on paint thickness as defined on the paint checklist.  Maintenance MWO defines the requirements along with a modification work order, a QC Checklist is completed as part of the requirements Note unit ELD 1576 final ABS was not signed by technician. M750 ELD 1418 Paperwork included includes acceptance inspection, road test, all parts requiring repair are identified and corrected. 350 GPM Pump An approved refurbishment procedure is available ELI 210-rev 8 along with associated checklists completed for work. A final pressure test is performed of the repaired pump using calibrated gages.  
 Form: MSBSF43000/1.1 - 0506
Report: UQA0111079/0109 - 26-Jan-09
Page 9 of 28
      Assessment of: ivieceR/gnisahcrPu ngAuditee(s):Robert Buckles
Audit trails and sources of evidence: Purchase Orders G054176, 54423 Receiving records rls9-0071, rls9-0055, Evaluation and conclusions: Purchasing Request is received in the stores from the foreman and the stores raise a PO against the supplier, upon receipt a QC 9 is generated with the evidence of inspection. Note Sherwin Williams requires C of A but this is not defined as a requirement in PO Government material This is received in Puridiom with Class 9 material received. Material is issued via a QMF 033.   C re QC Technician. Assessment of: alibrationAuditee(s):Joey Cadie
Audit trails and sources of evidence: Calibration Records Reviewed ELD 1084 11/08-11/09; ELD 1034 3/08-3/09, 306 2/08-2/09 Torque wrench, pressure 312 2/08-2/09, 1069 3/08-3/09, tachometer 6/08-6/09, ELD1020, ELD 1019 6/08-6/09  Evaluation and conclusions: Calibration Original copies of certificates ore held in Ladysmith with the system being controlled from the Alexandria HQ. RC 0901RAB08 It was observed that Instrument ELD 1034 was found out of tolerance for Relative Humidity with no review of how this affected previous inspections.    
 Form: MSBSF43000/1.1 - 0506
Report: UQA0111079/0109 - 26-Jan-09
Page 10 of 28
      Assessment of: Quality RecordsAuditee(s):Joey Cadiere QC Technician. Maintenance Audit trails and sources of evidence: 350 GPM Pump Records M200 A1
Evaluation and conclusions: Quality Each completed repaired unit has a relevant file with quality records maintained including Shipping Documentation DD 1149 ELF 161 ELI210 Paint paperwork Final Inspection Quality Inspection Checklist.  Maintenance Minor NC 0901RAB09 It was observed that the additions to the Ladysmith facility are now completed with the facility now including permanent wash, blast and paint booths with the respective operating equipment. Although a maintenance contract was in place to have an external body Ingersoll Rand perform maintenance of pumps and compressors the maintenance of the ancillary equipment was in development along with associated records. e. . Paint Booths. Blast facilit   
 Form: MSBSF43000/1.1 - 0506
Report: UQA0111079/0109 - 26-Jan-09
Page 11 of 28