A special process refers to a production or manufacturing procedure where the final product’s quality cannot be confirmed through standard inspections or testing after completion. This means that the outcome cannot be verified without using destructive methods that would compromise the product. As a result, the process must be rigorously controlled and validated to ensure that it consistently meets the required standards.

The purpose of this article is to provide guidance on how to implement a system that manages Special Process in line with AS9100/Nadcap requirements.

Example of special processes include operations like welding, heat treatment, or the fabrication of composite materials, where internal attributes cannot be easily assessed post-process.

Capturing Customer Requirements

The procedure shall be established to ensure that customer requirements identified through gap analysis are effectively captured and integrated into the organization’s existing documentation. This procedure will begin with a thorough review of customer needs, as outlined in the gap analysis, to identify any discrepancies or areas for improvement. These requirements will then be systematically incorporated into the relevant documents, ensuring that all aspects of the customer’s needs are addressed and reflected accurately in the organization’s processes.

Approval List

The process will include the creation of a detailed approval list, specifying who is responsible for reviewing and authorizing any changes to the documented information. This list will ensure that all modifications are vetted by qualified personnel and are aligned with organizational standards and customer expectations. By clearly defining the approval workflow, the organization ensures that all changes are properly scrutinized and validated before implementation.

Personnel Competencies and Certifications

In addition to the approval list, the procedure shall define the necessary competencies and certifications required for personnel involved in implementing changes based on customer requirements. This ensures that only individuals with the appropriate qualifications handle critical aspects of the process. By establishing clear competency and certification requirements, the organization maintains high standards of quality and compliance throughout the project.

Pre-Implementation Verification

Before initiating any project, the organization will verify that all required competencies, certifications, and customer qualifications are in place. This pre-implementation verification process will include assessing whether all team members possess the necessary skills and credentials, as well as ensuring that any third-party suppliers or sub-tier partners meet the required qualifications. This step is crucial for mitigating risks and ensuring that the project adheres to the highest standards of quality and compliance from the outset.

Sub-Tier Supplier Qualifications

Finally, the procedure shall address the qualifications and certifications needed for sub-tier suppliers involved in the project. This includes a thorough evaluation of the suppliers’ credentials and ensuring that they meet the necessary requirements before engaging them in the project. By implementing these measures, the organization ensures that all parties involved are adequately qualified and capable of meeting customer requirements, thus upholding the integrity and success of the project throughout its duration.

Download Our Procedure

To get started, you can download our procedure for free by following [this link](#). For a more detailed procedure that includes three comprehensive templates, please click here. The templates provided are:

• • Procedure Ready to Use: A complete, ready-to-implement procedure document.
  • Gap Analysis Template: A structured format for identifying and documenting gaps in customer requirements.
  • Approval List Template: A template for creating and managing the list of personnel responsible for reviewing and approving changes.
  • Approved Suppliers List (QASL) Template: A comprehensive list template for managing and verifying the qualifications of approved suppliers.

DOWNLOAD HERE

These tools will assist you in effectively implementing the procedure and ensuring all customer requirements are met with precision.

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