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Date: 04/05/2015 NucSIG Event – 9 th June 2010 Poor Supplier Quality Performance, Electrical Switchgear Paul Murphy CEng, CQP, MCQI Management Systems.

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Presentation on theme: "Date: 04/05/2015 NucSIG Event – 9 th June 2010 Poor Supplier Quality Performance, Electrical Switchgear Paul Murphy CEng, CQP, MCQI Management Systems."— Presentation transcript:

1 Date: 04/05/2015 NucSIG Event – 9 th June 2010 Poor Supplier Quality Performance, Electrical Switchgear Paul Murphy CEng, CQP, MCQI Management Systems Manager Dounreay Site Restoration Ltd

2 Date: 04/05/2015 Project – New Fuel Cycle Area Ventilation System Electrical Installation IAW Site’s Electrical Supply Policy: Progressively standardise the Site’s Electrical Distribution System & Components. Major worldwide Supplier selected. No significant problems prior to 2009.

3 Date: 04/05/2015 Supply Chain  Local Contractor installing new FCA Ventilation System.  Electrical Supplier providing assembled Switch Boards.  Electrical Supplier’s European Subsidiary supplying Assembled Circuit Breakers.  Various Sub Suppliers proving sub components.

4 Date: 04/05/2015 Procurement Controls Applied Adequate Specification Vendor assessment Large Reputable Established Company (not the cheapest!) ISO 9001 Certification Good previous performance Sample Witness of Factory Acceptance Tests Goods Inwards Checks & Storage Change Control 

5 Date: 04/05/ off 415v Switch Boards for New FCA Vent System.

6 Date: 04/05/2015 Moulded Casing Circuit Breakers were an ‘improved’ design using new sub components from new sub component suppliers. The Boards and Breakers had multiple defects indicating multiple Supplier Quality Failures

7 Date: 04/05/2015 Broken Door Handles & Safety Latches Safety Interlock Negated: –Padlocked Breaker Access Door could be opened.

8 Date: 04/05/2015 Broken Door Handles & Safety Latches Safety Interlock Negated: –Door could be opened when the breaker was closed.

9 Date: 04/05/2015 Breaker Mechanisms Out of Tolerance Hook Springs meant that two units failed to reset after tripping

10 Date: 04/05/2015 Base Unit Boss – Broken & Glued!

11 Date: 04/05/2015 Broken Boss Might have been caused by a Twisted Racking Shaft

12 Date: 04/05/2015 Or out of Tolerance Latch Guide …. smear of glue on the shaft caused glued repair to break as shaft rotated.

13 Date: 04/05/2015 Watch your Fingers – Live Bus Bars!

14 Date: 04/05/2015 Consequences for DSRL  Project Delays / Costs - loss of fee.  Ventilation failure in service can result in evacuation of Fuel Cycle Area & Contamination of Facilities (£100k +).  Regulator interest.  Loss of confidence in spares.  Reassess future contracts, cost of re-tendering, objective of standardising questioned.

15 Date: 04/05/2015 Causes and Resolution  Causes – Multiple quality Failures –Redesign; Metal Components replaced with Plastic. –New Sub Component Suppliers could not meet tolerances. –Inadequate Quality Planning:  Sub Component Inspection; new suppliers.  Factory Acceptance Testing.  Incomplete and incorrect Quality Documents & Test Records. –Attitude of Supplier’s management and workforce (e.g.: cost over quality:- plastic components and lack of adequate inspection. Glued repair, mechanical problems obvious but tolerated / misunderstood, etc.).  Resolution –Design changed back to metal components. –Designed to accommodate greater tolerances. –Adequate and appropriate inspection throughout. –Tool box talks.

16 Date: 04/05/2015 Epilogue –Supplier Open, Helpful and Cooperative. –Remedial actions satisfactory  Rework and repair.  Previously installed units checked and found OK –Corrective Actions Implemented. February Interlock Problems with the next set of Breaker Units. HOWEVER!

17 Date: 04/05/2015 Shutter Prevents ‘Closed ’ Withdrawal / Insertion

18 Date: 04/05/2015 Retracts to allow withdrawal when Breaker is Open

19 Date: 04/05/2015 But sometimes the Shutter doesn’t fully retract when open

20 Date: 04/05/2015 Or doesn’t drop down when Breaker is Closed!

21 Date: 04/05/2015 The Worrying Bit 1995 Wylfa Judgement  Establishes that Nuclear Site Licensees have absolute responsibility for conformity of purchased items used on their sites.  Licensees must demonstrate that they have taken all reasonable actions to ensure conformity. Do We?

22 Date: 04/05/2015 What are Other Industries doing?  Consider the copies of AS9100C handed out.  Please Read the Forward.  AS9100C overlays (BOLD) ISO 9001 with specific additional / clarified requirements for aviation space and defence. (Similar standards for medical devices, etc.)  What additional requirements in Section 7.4, ‘Purchasing’ might have helped us avoid the supplier assurance problems discussed? DO WE THINK THAT THE NUCLEAR INDUSTRY SHOULD HAVE SOMETHING SIMILAR?


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