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AS9100 8.5.1 j) - Lot splitting - any loopholes?

#1
8.5.1 j) the accountability for all products during production (e.g., parts quantities, split orders, nonconforming product);

I'm the new guy on the block, in a shop that just went to AS9100, and today I found a batch of 20 pieces shipping with a traveler for 40 pieces.

The shipping guy says he put the balance to stock with a copy of the 40 piece traveler.

I told him it's not an issue today, but explained the AS9100 requirement above to him, and told him I'd look into it.

So, before I tell them they've got to change their evil ways ... baby ... is there any loophole because the parts have completed the production stages and are now finished goods? I don't mind bringing them up to speed, I'm just preparing for possible counter arguments.

Can't tell you folks enough how much I appreciate you -
 

Al Rosen

Staff member
Super Moderator
#3
8.5.1 j) the accountability for all products during production (e.g., parts quantities, split orders, nonconforming product);

I'm the new guy on the block, in a shop that just went to AS9100, and today I found a batch of 20 pieces shipping with a traveler for 40 pieces.

The shipping guy says he put the balance to stock with a copy of the 40 piece traveler.

I told him it's not an issue today, but explained the AS9100 requirement above to him, and told him I'd look into it.

So, before I tell them they've got to change their evil ways ... baby ... is there any loophole because the parts have completed the production stages and are now finished goods? I don't mind bringing them up to speed, I'm just preparing for possible counter arguments.

Can't tell you folks enough how much I appreciate you -
I would not look at it as splitting the lot since you completed all 40 pieces. All 40 could have been put into inventory and 20 pulled for the shipment. 20 remain in inventory.
 

Eredhel

Quality Manager
#4
I want to make sure I understand the question correctly. You have an order with good traceability while it's being produced and once it's finished being produced, and prior to shipping, you decide to send half and stock half?
 
#6
If you know the part lot in inventory is completed and maintains any traceability requirements and the delivered part lot was good, I see no issue (the customer was OK to receive a part lot?)
 
#7
I want to make sure I understand the question correctly. You have an order with good traceability while it's being produced and once it's finished being produced, and prior to shipping, you decide to send half and stock half?
Yes - I believe there may be minimum lot make sizes that drive running more parts than the order requires, but the customer will come back and ask for more at a later date.

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" If you know the part lot in inventory is completed and maintains any traceability requirements and the delivered part lot was good, I see no issue (the customer was OK to receive a part lot? "

Yes, parts are completed and traceability is intact, customer is content. It's just been a long time since I was involved in lot splits and I wonder if this is a landmine for an external auditor, or a non-issue.
 

Eredhel

Quality Manager
#8
I don't think you need a loophole. Just continue the good traceability. Right now any partial order we send to stock we put a tag with the parts that includes the Work Order # (traveler #/job #) and material heat lot #, and then we put a copy of the MTR and a copy of work order page with the parts on the shelf. I think the copies are overkill since having the WO # gives us the traceability we need to get inspections done, part numbers & revisions, drawing numbers & revisions, heat lot #, et cetera. Plus we scan docs onto the server so having the WO# gives us what we need to pull up any necessary docs as well.
 

Pjservan

Involved In Discussions
#10
There really is no loophole except for potential holes in your system. What you want to make sure that if you allow for lot splits then you want to make sure that the traceability is maintained. Furthermore, specially if the "split" happens in the middle of the production run, your system needs to show how for the accountability of the parts.

One way to test your system is look for examples of "splits" in your systems, look at the paperwork/records and see if you are able to tell what happened with the orders. If you can go through the files and have a clear picture of what happened I will say you have a system that works for you.
 
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