H2C130-H1X130 Specials Aug 2014 amendment 1 · Summary of examples, records, results, etc. viewed:...

Job No.H2C130 / H1X130

Form No. BSF295 Issue Date; 23/07/14 Page No. Page 1 of 15

BASEC SURVEILLANCE AUDITREPORT

Client’s Name: Prysmian Cables & Systems Ltd, SpecialCables

Address: Chickenhall Lane, Bishopstoke, Eastleigh,Hampshire, SO50 6YU

Date(s) of the Audit: 4th – 5th August, 2014

This report has been prepared by:

Name to be added

Alastair Archibald

Tel; +44 (0)1908 267300

Email; [email protected]; www.basec.org.uk

BASEC

Presley House

Presley Way

Crownhill

Milton Keynes

BuckinghamshireMK8 0ES

The contents of this report are confidential to the company, as named above and BASEC

The nonconformities and opportunities for improvements contained within this report are the result of limited sampling

and therefore it cannot be assumed that others do not exist

The signature of the company’s representative indicates their agreement and understanding of the nonconformities and opportunities for improvement found during this audit

If there are inaccuracies, errors or queries regarding this report or audit findings,

please contact BASEC Head Office on +44 (0)1908 267300 within five working days of the closing meeting (E&OE)

mailto:[email protected]

http://www.basec.org.uk/



Executive SummaryThe following should be included; positive points / brief details of any findings / particularly any trends detected / details of anyimprovements noted / overall conclusion.

This report details the findings of an integrated ISO 9001 : 2008 and PCR 2.6 : Issue 6 Surveillance Audit ofPrysmian Cables & Systems Ltd, Special Cables

The audit duration was for 2 days and consisted of the following main activities;

Management system activities

Cable production witness

Detailed below, is a summary of the identified audit findings;

Category No. Details of findingsMajor Nonconformity 0 X

Minor Nonconformity 4 AA1: Clause Q7.5.1: The company did not comply with the clause in that aprocess was witnessed outside established control parameters. Objectiveevidence: drawing line 8001 air pressure seen to be set at 8.9 bar. ProcessInstruction 8001-371 states that the air pressure for this wire should be 10bar with no tolerance given.

Clause Q7.6: The company did not comply with the clause in that a pieceof monitoring and measurement equipment was not controlled. ObjectiveEvidence: Micrometer S/N29383, used to measure wire diameter on wiredrawing line 8001, has no company equipment identification orcalibration status label.

Clause Q4.2.3: The company did not comply with the clause in thatuncontrolled document changes were seen. Objective Evidence: Unsignedhand amendments were seen to R0M20 and XM23 settings of Buss 2compounder control sheet 3100SNVNL (3100 SV Natural) Issue 4 11/06/12

Clause Q7.5.3 The company did not comply with the requirements of theclause in that some product was seen with incorrect identification.Objective Evidence: A drum of BS EN 50525-3-41 Clause 4.1 Table B11x25mm cable (6491X) with drum code LC6244788 was seen to be markedwith cable code 6491B

Opportunity for improvement 1 Clause Q7.6: Abrasion machine not currently in use, but it is not identifiedas such pending formal inclusion in the company equipment list.

Recommendation:

The Documented Management System appears to be effective with no major findings identified.

Consequently, continued registration to ISO 9001 : 2008, and PCR 2.6: Issue 6 is recommended

Major NCs 0 Minor NCs 4 OFIs 1



Visit Summary

Existing scope:

Corporate Management and Administrative functions for the design, development, manufacture,installation and supply of cables and cable accessories.The design, development, manufacture and supply of the following cable and product types:Energy cables for special / industrial / fire performance applications up to 1.1KV using PVC & polymeric &elastomeric compounds. Cable accessories for use on land and submarine system up to 550 KV.The design, development and supply of the following product types:Energy cables for use up to 400 KV.The design, development and manufacture of the following product types:Low smoke and special cable compounds.The design, installation, supply, project management and maintenance of the following:Power transmission and distribution cable installations rated up to and including 600 kV, includingassociated telecommunication cable systems.

Certificate Valid Until Date:

CSI-084 valid until 11/08/17PCR-084 valid until 11/08/17

Other changes, e.g. name, address, etc.

None detailed

Number of employees (FTE within scope):

186

Visit duration (In Days):

2

Relevant standard(s):

ISO 9001 : 2008 / PCR 2.6, Issue 6

The visit had the following conclusion:

Minor NCs and Comments have been raised

The following action should be taken by the client:

Comments to be considered and action taken where appropriate. CAPs to be fully completed andretained by the client, Minor NCs to be actioned in a timely manner.

BASEC Audit Team Client Representative

Name: Alastair Archibald Name: Andrew Watt

Signature: Signature:

Date: 05/08/14 Date: 05/08/14



Verification of Closure of the Corrective Action For The Findings From ThePrevious Audit

The corrective action with regard to the findings from Report No. H1C1A130, Dated 28/05/14, werereviewed and verified.

No. Objective evidence Status(Closed / Open)

1 ISO9001; Clause Q4.2.3; Minor NC;a) Compound Mix Card KS2012 dated 07/01/14 now shows details for

DP8 including mix ratios, temperature, RPM, pressure and final ramposition.

b) Process Instruction 8000-551 iss 1 01/07/14 for Berol 1820 labextruder issued to cover DP8 material. Procedure includes detailedsetup instructions.

c) Die Selection Sheet for M/C 8004 + 8005 issue 1, July 2014, seen.This is available on the relevant production lines’ intranet system

Closed

2 ISO9001; Clause Q7.5.1; Minor NC;Cause of problem was the design team accepting an email as authorizing aproduct change instead of POMS. Andy Wynn (Compound and DevelopmentEngineering Manager) called a meeting of the design staff during the audit toinstruct that from now on only POMS can be used to authorize a change. Theend of this meeting was attended by the auditor, and the staff all agreed thatthis was now understood.

Closed

3

4

5

6

7

8

9

10

All actions were accepted as effective and the Corrective Action Plan was signed off.

Notes;

If the company cannot demonstrate that they have implemented effective corrective action, then the finding needs to be re-issued as a new finding, with a newfinding number and escalated to the next level, for example, a Minor NC will become a Major NC.

Bear in mind that the corrective action may not be fully completed, however, if the company can demonstrate an effective management plan for the control of thefinding with a defined due date for completion, then this may considered as effective and need not be re-issued.

PCR Clause Nos. are prefixed with P

QMS Clause Nos. are prefixed with Q

EMS Clause Nos. are prefixed with E

OHSAS Clause Nos. are prefixed with H



Opening / Closing Meetings

The objective of the audit is to investigate and determine the degree of compliance of the client’s documentedmanagement system (DMS) with the requirements of ISO 9001 : 2008 / BASEC Product CertificationRequirements (PCR) 2.6 : Issue 6 and the appropriate interpretive documents, as well as to gain evidence to theextent to which the DMS is being implemented effectively, as applicable to the scope of certification as detailedon Page 3. The audit is based on samples and methods to collect information include, but are not limited to;

Interviews

Observation of processes and activities

Review of documentation and records

The opening and closing meetings were attended by;

Andrew Watts

Alastair Archibald, BASEC Lead Auditor

All Opening / Closing Meeting Checklist items as per Form BSF266 were discussed and no issues were raisedwith the exception of an incorrect company scope detailed in the BSF139.011 Visit Checklist

The outline of the audit programme was discussed and agreed with the client

Standards audited for this visit are PCR 2.6:Issue 6 / ISO9001:2008

PCR Clause Nos. are prefixed with P

QMS Clause Nos. are prefixed with Q

Total number of employees (FTE) = 185

Confirmed if there are any operational shifts and the number of employees per shift

Confirmed that there are no seasonal variations to the number of employees.

Certificate Nos.

Scheme Cert. No. VUD

PCR PCR-084 11/08/17

QMS CSI-084 11/08/17

Confirmed the following scope:

Corporate Management and Administrative functions for the design, development, manufacture, installationand supply of cables and cable accessories.The design, development, manufacture and supply of the following cable and product types:Energy cables for special / industrial / fire performance applications up to 1.1KV using PVC & polymeric &elastomeric compounds. Cable accessories for use on land and submarine system up to 550 KV.The design, development and supply of the following product types:Energy cables for use up to 400 KV.The design, development and manufacture of the following product types:Low smoke and special cable compounds.The design, installation, supply, project management and maintenance of the following:Power transmission and distribution cable installations rated up to and including 600 kV, including associatedtelecommunication cable systems.



No major changes to the system have been made.

Audit Detail Summary

Process sampled: Management system

Summary of examples, records, results, etc. viewed: Quality manual, document hierarchy, various documentsseen during the audit.

The document control system, quality manual and quality policy all appear to give a firm framework for thecompany’s activities.

Notes:

Provide a summary of the audit of this process, including:o Positive commentso Negative commentso Overview of any findings raisedo Details of any trendso Details of any improvements




Process sampled: Management responsibility

Summary of examples, records, results, etc. viewed: Organisation chart, authorization of documents andforms,

Notes:





Process sampled: Management controls

Summary of examples, records, results, etc. viewed: Internal audits, corporate management review,internal KPI progression, weekly, monthly and quarterly quality reports.

The corporate targets for in-process nonconformities and customer complaints appear to be diligentlypursued and to provide for improved quality reliability, without over-burdening the company with too manymetrics.

Internal audits seen are detailed and thorough, and nonconformities have been seen to be followed up well.The new scoring of internal audits to align with the corporate audit procedure QP-DQ-QS-004 issue 2 shouldaid alignment of company goals with corporate expectations.

Notes:





Process sampled: Resource management

Summary of examples, records, results, etc. viewed: Training records.

Training records seen for several operators interviewed during the audit. The inclusion of test questions for thetrainee to demonstrate his or her understanding is a good adjunct to the training programme, as is requiringthe auditor to suggest ways in which the training might have been better understood.

Notes:





Process sampled: Production activities

Summary of examples, records, results, etc. viewed: Process instruction, test records, test equipment,machine settings, traceability labelling, storage conditions, signage, general housekeeping, wire drawing,stranding, insulation extrusion, bedding extrusion, lay-up, taping and armouring

The general condition of the factory and its production equipment. With the exception of two minordocumentation nonconformities (AA2&4), the control systems appeared to be working well.

Operators were seen to be open and helpful, and they appeared knowledgeable about their work. Control ofnonconforming product and traceability appeared to be particularly well-controlled.

The marking issue identified in NC AA5

Notes:





Process sampled: Monitoring and measuring equipment

Summary of examples, records, results, etc. viewed: Calibration records and labels

The system generally appeared to be working well, with internal calibrations carried out using traceablecalibrated equipment whose calibration status could be traced back to national standards. External calibrationcertificates seen were all stamped as reviewed and accepted by R. Perdue, the Instrument technician.

One minor nonconformity (AA3) was seen concerning a micrometer used for diameter checks on a wire drawingline, but otherwise calibration was well controlled.

Notes:





Process sampled: Record control

Summary of examples, records, results, etc. viewed: Various records at all stages of production.

The company intranet system and automatic line data capture appears to be an effective way to ensure recordsare kept securely, prevented from amendment and are easily retrievable.

Notes:




Sample Selection And Pick-up

Scheme and sample selectionScheme A No. required 8 Selected 8 Shortfall 0 Produced km 13003

Scheme B No. required 9 Selected 9 Shortfall 0 Produced km 11952

Scheme No. required Selected Shortfall Produced km

Special samples selected1 x 50m BS EN 50525-3-41 required for Smoke and Acid Gas testing – this was available1 x 1m BS EN 50525-3-41 required for Ozone testing – this was available.1 x 15m BS7629-1:2008 sample required for Smoke and Acid Gas testing – this was available1 x 1m BS7629-1:2008 sample required for Ozone testing – this was available1 x 5m BS6724:1997 +A3:2008 sample required for Smoke and Acid Gas testing – this was available1 x 5m BS7846:2009 sample required for Smoke and Acid Gas testing – this was available1 x 5m BS6724:1997 +A3:2008 sample required for Smoke and Acid Gas testing – this was availableNo BS8436 samples due to no production of this specification of cable since the last visit.

1 Give details of products bearing the BASEC Mark that were seen in production (If none, state type of product seen);

BS7846:2009 1x25mm2 G/Y XLPE insulation extrusionBS7846:2009 1x25mm2 Blue XLPE insulation extrusionBS6724:1997+A3:2008 3 x 35mm2 lay-upBS6724:1997+A3:2008 4 x 35mm2 armouring

2 a. Give details of any products bearing other company’s name and the BASEC Mark;

None

b. Give details of any parts of the product subcontracted;

None

3 a. Give details of tests witnessed;

None

b. Give details of the test equipment (Calibration status, condition of the equipment);

All test equipment viewed was seen in good condition and calibrated, with the exception of one micrometer on the wiredrawing line 8001

4 Have corrective actions for a product routine sample failure been taken and has report been completed;

N/A

5 Give details of any changes that have been made to certified products which may affect compliance with the conditions ofcertification;

None



UKAS Registration And BASEC System And Product Certification Marks

The marks seen in use were correctly used.

Corrective Action Plan

This was discussed with the client and copies left with the client for them to complete, which will be reviewedand verified at the next BASEC audit.

End of Audit



Process Matrix

Audited ProcessesPossible elements

PCR 9001 14001 18001

XManagement system

ScopeProcesses

Documentation and controlManual

ScopeDescription of elements

Documentation and control

XManagementresponsibility

PolicyResponsibility

RolesAuthority

CommunicationCommitment

Customer Focus

XManagement controls

Management ReviewInternal audits / actions

Process monitoringCustomer FocusAnalysis of data

ObjectivesContinual improvementComplaints - customers

Management reviewInternal audits / actionsPerformance measures

Legal complianceParticipation & consultationCommunication / complaints

Objectives / Management plans

Resource managementHuman / competence

InfrastructureEnvironment

Potential impactCompetence

Task impactCompetenceEvaluation ofeffectivenessPotentialconsequencesLanguage /literacy

Customer processesSpecified requirements and review

Customer satisfactionCustomer communication

AspectsImpacts

Legislation /compliance

HazardsRiskassessmentsControlsHierarchyLegislation /compliance

Design Planning, inputs, outputs, review, verification, validation,changes

Operational controls

Monitoring

Incidents / investigationProcurement

Supplier evaluationPurchasing information

Verification

XProductionxx

Copper rod productionWire drawingCable productionCable testingProduct monitoringNC productCorrective and preventiveaction

Control and planningValidationIdentification/traceabilityCustomer propertyPreservationDoc controlMonitoring and measuringNC product

Operational controls

Monitoring

Incidents / investigation

XMonitoring and measuringequipment

CalibrationIdentificationTraceability

Calibration

X Control of records

IdentificationStorage

ProtectionRetrievalRetention

Disposition

Notes;

Column 1 - An ‘X’ confirms that the process been covered in the report for the standard(s) applicable to the visit. The details in the relevant section of the reportshould contain summary information to confirm the process has been covered.

Column 2 - Identifies the process. For the production process this should be as defined by the organisation.

Columns 3 - 6 - Identify the possible elements that could be covered under the process.

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