Unauthorized Changes Within Qualified Special Processes
Published .
Related
- AS9100
- Nadcap
Topics
- special-process
- process-change
- fai
- nadcap
- supplier-control
- configuration-management
A supplier performing a qualified special process, such as painting or adhesive bonding, identified an opportunity for improvement. This involved either substituting an ancillary material like a primer or introducing a new tool, such as a custom masking fixture. Believing the change to be minor and beneficial, the supplier implemented it without formal notification or engineering approval from the customer.
The alteration, while not changing the primary process material, constituted an unauthorized change to a qualified and frozen process. Special process approvals (e. g.
Key Takeaways
- The unapproved change was identified during a subsequent audit or part inspection, leading to the product being declared non-conforming.
- This necessitated a formal investigation, process re-validation, and potentially a new First Article Inspection (FAI), causing production delays and administrative burden.
- The alteration, while not changing the primary process material, constituted an unauthorized change to a qualified and frozen process.
Best Practice
Any change to a qualified special process, including ancillary materials, tooling, or methods, must be formally evaluated per AS9102 requirements. Suppliers must obtain documented approval from the customer's engineering authority prior to implementing any such changes to ensure process integrity and product conformity.
Reflects the recommended position based on community discussion and expert review.
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