FYI - welds can be x-rayed. I know there is portable equipment available that is used for construction (but no idea on the $$).
We're currently 9002 certified and received a bang on this from an auditor about a year an a half ago.
The finding:
Contrary to requirements stated in Section 9.0 of the Quality Manual, processes which cannot be fully verified by subsequent inspection have not in all cases identified and qualified. Example: The ___ Process has not been identified as a process which would need to be qualified and records of qualification for the process were not available.
Further, it was not clear if the requirements for qualification of these processes had been defined (who is responsible for the qualification, what tests need to be performed, what records need to be retained, when would the process need to be revalidated, etc.). (Re: ISO 9002, Section 4.9)
The ensuing discussions involved experts from Plant/Corp and R&D; the key thing to keep in mind is what your company has identified as being prudent and cost effective.
Cause of nonconformity:
After review at plant, information sent to DNV Auditor for review. Based on this data (see attached) the first part of the nonconformity was dropped.Second paragraph detail was not adressed in the QCP.
Corrective Action Response:
ECO (#0001235) change to QCP-900. Add New Section 4.1 “When a process is added or redesigned, the Engineer responsible for the new or changed process will determine if it qualifies as a special process. If so, the Engineer will involve the approptiate personnel to satisisfy the requirements of section 5.3. If not, the Engineer will document that the process does not meet the requirements to be called a special process.”
Implementation of the standards does not expect you to go bankrupt trying to measure 'special processes'. As for certifying the welders, there are usually area tech schools that offer training, but rememeber that any training for competence is what your company determines is required. If you design an in-house program and certify your welders to that I think it would still meet the requirements as long as that is specified (though it may not be the best solution).
