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DI-MGMT-81986

Critical Characteristics Control Plan (CCCP)

The Critical Characteristics Control Plan (CCCP) describes how the Contractor and subcontractors will prevent, detect, and control critical non-conformances as part of the Contractor's quality system.

Approval DateJuly 14, 2015
AMSC NumberN9563
Preparing ActivitySH
Project NumberMGMT-2015-005
OPR—
DTIC ApplicableNo
GIDEP ApplicableNo
Limitation—
Applicable Forms—
Approval Limitation—
Form Version—
DID Formatfree_text
963C CompliantYes
DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited.
Supersedes
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Related
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Description & Purpose

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Application & Interrelationship

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Use & Relationship

The Critical Characteristics Control Plan (CCCP) forms a part of the Contractor's quality system and describes how the Contractor and all subcontractors will prevent the creation or occurrence of a critical non-conformance (defect), but in the event of its occurrence, assure its detection and control.

This Data Item Description (DID) contains format and content preparation instructions for the data product generated by the specific and discrete task requirement as delineated in the contract.

Preparation Instructions

1Reference documents.The applicable issue of the documents cited herein, including their approval dates and dates of any applicable amendments, notices, and revisions, shall be as cited in the current issue of the DODISS at the time of the solicitation; or, for non DODISS-listed documents, as stated herein.
2Format.The plan shall be in the Contractor's format.
3Content.The plan shall include a cover sheet specifying the following: a. Contractor's title b. Contract number. c. Revision and date. d. Nomenclature of the system/component/program/project, the security classification, and the distribution restrictions. e. Government activity issuing the controlling contract.
3.1Table of contents.The plan shall contain a table of contents.
3.2Index.The plan shall include an index.
3.3Descriptive material.The plan shall include any descriptive material needed to provide comprehensibility of the content such as sketches, drawings, photographs, tables, forms, graphs, worksheets, charts, etc.
3.4Key manufacturing processes.The plan shall identify those aspects of the manufacturing process that can influence the creation of a critical non-conformance including the production process, work instructions/procedures, process controls, mistake proofing, inspection systems (Acceptance Inspection Equipment (AIE), Automated Acceptance Inspection Equipment (AAIE)), materials, material handling, personnel, training, and the quality management system (calibration, corrective/preventive action, control of non-conforming product, and supply chain management).
3.4.1The plan shall list all of the critical characteristics, the location/facility which produces the material affected by each critical characteristic, and the associated document(s) identifying the requirement (specification and revision, quality assurance provision (QAP) number, drawing and revision).
3.4.2The plan shall contain the critical characteristics management structure and roles/responsibilities including:
3.4.2.1An organization chart addressing the critical characteristics control structure.
3.4.2.2Personnel performing Quality Assurance (QA) inspections and verification inspections.
3.4.2.3Relevant QA inspection validation.
3.4.2.4Material Review Board (MRB) authority.
3.4.2.5Access/disposition to critical non-conformances, accountability, and traceability.
3.4.2.6Work stop authority.
3.4.2.7Restart authority.
3.4.2.8Notification to Government authority.
3.4.3The plan shall contain the program management structure and roles/responsibilities including:
3.4.3.1An organization chart with supporting narrative describing the management office the Contractor establishes to manage the contractual commitments.
3.4.3.2The direct lines of control, responsibilities, functional relationships, and authority between the management office and the Contractor's other organizational elements.
3.4.3.3All interfaces between the Contractor and the Government and between the Contractor and other Contractors which are necessary and pertinent to the accomplishment of contractual tasks, projects, and programs.
3.4.4The plan shall identify all appropriate critical process documents including:
3.4.4.1Manufacturing processes and procedures.
3.4.4.2Work instructions/procedures.
3.4.4.3Handling instructions.
3.4.4.4Process controls.
3.4.4.5Inspection systems and procedures.
3.4.4.6Accountability/traceability of non-conforming materials documentation.
3.4.4.7Quality records maintaining an audit trail.
3.4.5The plan shall contain detailed information about preventing critical non-conformances in the production process and it shall describe how the process is robust with high capability and effective controls including:
3.4.5.1Process description.
3.4.5.2Detailed flow chart including Inputs, Outputs, and Key Process Parameters.
3.4.5.3How key process parameters are identified, defined, and controlled.
3.4.5.4Failure Modes analysis methodology.
3.4.5.5Fail-safe methods, mistake proofing techniques, and assurance that the process is not bypassed.
3.4.5.6Process control tools.
3.4.5.7Feedback or in-process inspections.
3.4.5.8Material handling.
3.4.5.9Identification of Failure Modes and frequency of occurrence.
3.4.5.10Method to assess that the system is robust, capable, and under control (process prove-out; recent, relevant production data, SPC, etc.).
3.4.6The plan shall contain the schedule for routinely assessing reliability and effectiveness including:
3.4.6.1Frequency of verification (SPC, process capability, and audit schedules).
3.4.6.2Monitoring appropriate metrics and reactions to trends.
3.4.6.3Identification of actions to ensure process is reliable and effective.
3.4.6.4Frequency for assessing the reliability and effectiveness of the production processes.
3.4.7The plan shall contain a description of the inspection/verification system, equipment, and detailed information about preventing critical non-conformance escapes including:
3.4.7.1Contractor's process to verify that the design of the inspection/verification system is robust, capable, and effective to ensure that non-conformances are identified and correctly dispositioned.
3.4.7.2Material handling and accountability of non-conforming material.
3.4.7.3Methodology of inspection utilized (AIE, AAIE, visual, acceptance based on process control, etc.).
3.4.7.4Identification of MIL-STD-1916 VL VII validation system or alternate proposed method.
3.4.7.5Personnel involved in inspection and their required qualifications.
3.4.7.6Throughput of inspections utilized (AIE, AAIE, visual inspections, etc.).
3.4.8The plan shall identify any proposed referee gages and associated processes to include re-introduction of conforming material into the production process and maximum rates and quantities permitted for referee gages.
3.4.9The plan shall include a detailed flow chart including Inputs, Outputs, and Key Process Parameters and the following:
3.4.9.1Failure Modes of the inspection system.
3.4.9.2Fail-safe methods, mistake proofing techniques and assurance that the inspection system is not bypassed.
3.4.10The plan shall include calculations, documentation, and identification of the reliability and effectiveness of the inspection system including:
3.4.10.1Formula, methodology, or industry standard used to determine the inspection system reliability.
3.4.10.2The results of the demonstrated reliability based on the verification/validation for each inspection system.
3.4.11The plan shall identify the schedule for routinely assessing reliability and effectiveness including:
3.4.11.1Frequency and method of routine verification (when and how many times defect masters/salters are run through and/or audit schedules).
3.4.11.2Quantification of inspection system error rates.
3.4.12The plan shall address actions to be taken if the inspection system accepts a defect master/salter (constituting a failure of the inspection system) which would require the following actions:
3.4.12.1Segregate all material since the last successful verification.
3.4.12.2Investigate and implement corrective action to the inspection system.
3.4.12.3Verify suspect material does not contain any critical non-conformances.
3.4.12.4Update the inspection system's error rate and overall escape risk calculation.
3.4.13The plan shall detail test procedure(s) designed to demonstrate the error rate (reliability) of the inspection system and they shall also include:
3.4.13.1Identification of sufficient test quantities/samples sizes to assure minimum 90% statistical confidence.
3.4.13.2A schedule to routinely monitor the non-conformance and inspection system error rates to assure they do not exceed maximum rates allowed.
3.5Escape Risk Calculation.The plan shall contain non-conformance rates for each individual critical characteristic entering the inspection systems, the error rate of the inspection equipment associated with each characteristic, individual characteristic escape risks, and summative escape risk.
3.6The plan shall contain procedures to address the necessary actions to be taken if a critical non-conformance is found anywhere in the production process and shall include:
3.6.1How a non-conformance will be identified and segregated.
3.6.2A list of all personnel/positions responsible for identifying, segregating, and maintaining accountability/traceability for the critical non-conformances.
3.6.3Identification of all appropriate documentation, including records for disposition/accountability for tracking a critical non-conformance.
3.6.4Identification of personnel/persons responsible for, and records documenting the immediate shutdown of the operation that produced the non-conforming component/assembly, and if applicable, any other operations incorporating suspect product.
3.7The plan shall contain the process for immediately notifying the Government per the Contract Data Requirements List (CDRL) including the identification of personnel responsible for reporting critical non-conformances to the Government.
3.8The plan shall describe the process by which suspect material is identified, segregated, and prevented from additional use or shipment to the Government.
3.9The plan shall contain how and by whom an investigation will be conducted to determine the root cause of a non-conformance and required corrective actions.
3.10The plan shall describe the restart request process and use of any suspect material, including objective evidence of the failure analysis investigation, which will be provided to the Government as part of the restart request.
3.11The plan shall address what actions are taken, and by whom, for any critical non-conformance escape found beyond the designated inspection point prior to Government acceptance including:
3.11.1Providing the results of the root cause analysis and corrective action on the inspection system that allowed the critical non-conformance to escape.
3.11.2Providing updated inspection system reliability rates (error rates) and re-calculated total escape risk.
4Media requirements.The plan shall be in Adobe electronic Portable Document Format (pdf), version 2007-2010.

References

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