Defining and Controlling Special Processes
Published .
Applicable Standards
Related
- AS9100
- AS13100
- Nadcap
Topics
- special-process
- process-control
- supplier-quality
- nadcap
- source-approval
- flowdown
A supplier performed a manufacturing operation governed by an industry specification, assuming that since the final part features could be dimensionally inspected, the process did not require special oversight. This interpretation was based on the ability to perform post-process measurement.
The customer classified the operation as a special process because its conformance cannot be fully verified by subsequent inspection alone, creating a risk of latent defects. The supplier had not used a customer-approved or Nadcap-accredited source, violating contractual flowdown requirements.
Key Takeaways
- The failure to obtain prior process approval resulted in a nonconformance report and rejection of the hardware.
- The supplier was issued a corrective action to revise their procedures for identifying and managing special processes per customer and industry standards.
- The customer classified the operation as a special process because its conformance cannot be fully verified by subsequent inspection alone, creating a risk of latent defects.
Best Practice
Organizations must rigorously apply the definition of a special process from AS9100: one where the output cannot be fully verified by subsequent monitoring or measurement. This determination must be made prior to production to ensure all source approval and validation requirements, such as Nadcap accreditation, are met.
Reflects the recommended position based on community discussion and expert review.
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