CORPORATE STANDARD

CPS0495

SUSPECT NONCONFORMING-PART CONTAINMENT PROCESS

Date issued: 23 June 2016
Implementing divisions: Kenworth Truck Company, Peterbilt Motors Company, PACCAR Technical Center,
Dynacraft, PACCAR Engine Company

Scope

This standard defines the process and responsibilities for inspecting, containing, and validating parts or
purchased assemblies that might not be in compliance with PACCAR implementing divisional drawings,
specifications, or requirements.

Field of application

This standard applies to all suppliers of parts and assemblies installed on vehicles, engines, or subassemblies
manufactured or assembled by PACCAR implementing divisions.

References

3.1

PACCAR documents

PACCAR Supplier Quality Requirements Manual

CPS0495 Containment Documentation Workbook

3.2

Other references

ISO/TS16949, Quality Management Systems Particular requirements for the application of ISO
9001:2008 for automotive production and relevant service part organizations

ISO9001, Quality Management System Requirements

Terms

4.1
sweep
100% inspection of all assemblies or parts in inventory and in transit to a PACCAR facility
4.2
canvass
100% inspection of all assemblies or parts in inventory, in transit, or already installed at a PACCAR facility
4.3
clean point
First part or assembly with containment action performed
4.4
site lead
supplier representative at PACCAR facility responsible for containment actions

Page 1 of 6
2016 PACCAR Inc. All rights reserved. The information contained herein is proprietary to PACCAR Inc and shall not be reproduced,
copied, or disclosed in whole or in part, or used for manufacture or any other purpose, without the written permission of PACCAR Inc.
The only controlled version is that viewed electronically on the designated PACCAR intranet site.

PACCAR CORPORATE STANDARD

Number:
Date issued:

SUSPECT NONCONFORMING-PART
CONTAINMENT PROCESS

CPS0495
23 June 2016

4.5
sort
100% inspection of all assemblies or parts in inventory and in transit to a PACCAR facility

General

This standard establishes the containment process requirements when a supplier is directed by PACCAR to
inspect parts and assemblies because of a reported or potential nonconformance. This may come as (but is not
limited to) a request to canvass, sweep and/or sort of parts. PACCAR Supplier Quality Requirements Manual
and ISO/TS16949, 8.3 require control of nonconforming product. Unless otherwise specified by the
implementing division, this process must also be used when a supplier discovers a noncompliant part or
assembly that might be distributed in the supply chain.

Requirements

6.1

General

PACCAR Tier 1 Suppliers must plan, establish, communicate, and manage containment activity in compliance
with the requirements defined within this standard and the PACCAR Supplier Quality Requirements Manual.

6.2

Notification response

6.2.1

General

PACCAR requires closed-feedback-loop communication for all containment requests. A phone call followed by a
confirmation email is strongly recommended to acknowledge and coordinate containment. Failure to
acknowledge and act on containment requests is not permitted.
6.2.2

Supplier contacts

Supplier contacts responsible for ensuring supplier part conformance are to be documented on the PACCAR
Portal. These contacts must have the authority and ability to arrange containment actions upon notification.
Contact backups shall be delegated to ensure compliance with the containment process when primary contacts
are absent.
6.2.3

Response content

6.2.3.1 General
This section provides a minimum level of information required in response to containment request.
6.2.3.2 Nonconforming part data collection
As part of containment initiation, the Supplier shall obtain any required additional information from either the
issuing factory or onsite third party. The information may include, but is not limited to traceability data, key
inspection areas requiring photograph, safeguarding of part for further inspection by supplier personnel, or
return shipping guidance.
6.2.3.3 Affected locations
Supplier shall identify and notify all locations affected by the nonconformance and implement containment at
those locations in accordance with this standard. This includes parts that may be not yet be received by
PACCAR.

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PACCAR CORPORATE STANDARD

Number:
Date issued:

SUSPECT NONCONFORMING-PART
CONTAINMENT PROCESS

CPS0495
23 June 2016

6.2.3.4 Identification of Site Lead for containment

A supplier site lead must conduct the containment plan at all affected locations. The site lead shall be identified
with contact information. Site leads are responsible for executing onsite containment and reporting.
6.2.4

Containment planning

Suppliers shall develop a plan for containment using the check points shown in Figure 1. Containment shall be
maintained until confirmed conforming parts are received at the checkpoint.

Figure 1 Points of containment

6.3

Containment Preparation

6.3.1

General

The supplier shall ensure resources are available and prepared to start containment upon arrival at a PACCAR
facility (including contracted warehouses).
6.3.2

Personal protective equipment (PPE) and tools/equipment

6.3.2.1 General
The supplier is responsible for providing all required PPE, tools, and equipment as required by the plant or
manufacturing facilities of implementing division. Contact the Quality Department at the plant or manufacturing
facilities for current requirements.

2016 PACCAR Inc. All rights reserved.

Page 3 of 6

PACCAR CORPORATE STANDARD

Number:
Date issued:

SUSPECT NONCONFORMING-PART
CONTAINMENT PROCESS

CPS0495
23 June 2016

6.3.2.2 PPE
Minimum PPE may include, but is not limited to:

Safety glasses

Steel-toed shoes

Gloves

Hearing protection

Long Pants

6.3.2.3 Environmental Requirements

Supplier is responsible for identifying any environmental impact and obtaining required approval prior to
containment start. Examples include, but are not limited to:

Burn Permits

Chemical Usage (paints, solvents, cleaners, for example)

Additional Safety Requirements

6.3.2.4 Tools
Tools required shall be identified and available at the start of containment. Any required PACCAR tools or
resources (such as testers, lighting, etc.) shall be identified prior to supplier personnel arrival.
6.3.3

Supplier inspection instructions

6.3.3.1 General
All containment activity requires clear instructions using the current PACCAR Containment Inspection Work
Instruction form located in the CPS0495 Containment Documentation Workbook. The instructions shall provide
written and pictorial descriptions of the reported defect and method for verifying part conformance.
6.3.3.2 Availability
On site supplier representatives are to have or be provided a physical copy of work instructions and data sheets.
If formal work instructions are not available at the start of containment, the supplier is to ensure the inspector
understands:

the complaint

the acceptable/unacceptable conditions

requirement for marking parts

data collection requirement

Under no circumstances will inspections begin without clear understanding and acknowledgement of these four
items.
6.3.3.3 Distribution
In addition to the supplier inspection team members, inspection instructions are to be provided to PACCAR
Supplier Quality and PACCAR plant or manufacturing facility quality departments for information and review.

2016 PACCAR Inc. All rights reserved.

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PACCAR CORPORATE STANDARD

Number:
Date issued:

SUSPECT NONCONFORMING-PART
CONTAINMENT PROCESS
6.4

Inspection personnel requirements

6.4.1

General

CPS0495
23 June 2016

The supplier is responsible for the skill, training and performance of all inspectors conducting containment.
Additional or replacement inspectors may be required if containment performance is deemed not satisfactory.
6.4.2

Certification

Inspection company ISO9001 certification is desired, but not required at this time. However, the supplier is
expected to perform due diligence to ensure personnel used for containment have the capability to follow
instructions and use the tools required for successful containment.
The supplier shall ensure inspectors are qualified with any special certifications required to complete
containment.
6.4.3

Reliability

Nonconforming part containment shall be 100% complete and on schedule with no break in containment
because of tardiness or absence of supplier personnel.

6.5

Containment execution

6.5.1

General

Inspection shall be conducted in accordance with the Containment Inspection Work Instruction. Execution of the
containment plan shall conform to the requirements below.
Any nonconforming parts found already installed on any vehicle requires immediate notification of plant or
manufacturing facility Quality Department to ensure part is removed and replaced prior to shipment.
6.5.2

Personnel management

All containment team members shall agree to follow all local facility rules and requirements. Failure to follow
rules and requirements might result in removal and barring reentry into the PACCAR facility.
Trained team members must not be removed from containment activity without approval from PACCAR Supplier
Quality or Plant Quality Assurance.
All containment team members will sign the Containment Inspection Work Instruction signifying understanding
of its contents and expectations.
6.5.3

Part handling

Containment personnel must minimize risk of damage to parts, therefore only the minimum amount of parts
required for inspection will be removed from the protective packaging at any given time. The Site Lead shall
coordinate the inspection process with plant material handling to minimize impact to PACCAR personnel and
production.
Parts shall be placed in packaging exactly as received from the supplier/logistics center to enter the production
flow again. Parts and/or containers shall be handled in accordance with the special instructions in the
Containment Inspection Work Instruction or on the packaging itself.
If a container or rack is partially complete at the end of the shift, must not mix checked and unchecked parts in
the same container/rack.

2016 PACCAR Inc. All rights reserved.

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PACCAR CORPORATE STANDARD

Number:
Date issued:

SUSPECT NONCONFORMING-PART
CONTAINMENT PROCESS

CPS0495
23 June 2016

If nonconforming parts are found, plant QA or Materials personnel must be notified to ensure appropriate
disposition of parts. The supplier inspector is responsible to ensure nonconforming parts are identified prior to
removal from the inspection area for quarantining.
6.5.4

Documentation

The containment Site Lead is responsible for reporting all results to PACCAR and Supplier Quality Assurance.
An on-going running tally of sort/rework progress must be kept. Each result must be recorded on the data sheet
upon determination of part conformance. PACCAR may request status of containment results at any time,
therefore results must be readily available.
If containment personnel encounter a potential defect different from the defect defined in the work instruction,
the part will be immediately contained and PACCAR Quality Assurance notified for disposition.
Inspectors are to mark parts/packaging as instructed by the work instructions only after parts have been
inspected and determined conforming. Marking parts/packaging ahead of time will result in a requirement to
inspect all inventory (including marked inventory) again.
6.5.5

Break in containment

If plant QA determines containment has been broken, the supplier might be required to restart containment.
Examples of a break in containment include:

Inspector absence or negligence allowing uninspected parts to be used

Inadequate inspection instruction creating an ineffective inspection

Supplier delivery of precorrective action parts or assemblies after removal of containment

6.6

Results reporting

Containment Site Lead shall report results to PACCAR and Tier 1 Supplier daily.
The official PACCAR containment data sheets shall be provided to PACCAR Quality Assurance for
review/acknowledgement. All sheets are to be scanned as Adobe PDF files and compressed into an archive for
historical reference.
When containment actions are complete, the electronic archive files will be provided to PACCAR and the tier 1
Supplier for reference.

2016 PACCAR Inc. All rights reserved.

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