CRITICAL FLAW SIZE CRITICAL FLAW SIZE A size of flaw in a structure that will cause failure of the structure at the expected operational stress level. CRITICAL MANUFACTURING PROCESS A process that is mandatory for use during the manufacturing of an item and without which an acceptable item cannot be produced. CRITICAL NONCONFORMANCE A nonconformance that judgment and experience indicate is likely to result in hazardous or unsafe conditions for individuals using, maintaining, or depending upon the supplies or services, or is likely to prevent performance of a vital agency mission. CRITICAL SAFETY CHARACTERISTIC Any feature (such as tolerance, finish, material composition, manufacturing, assembly or inspection process, or product) that if nonconforming or missing could cause the failure or malfunction of the critical safety item. CRITICAL SAFETY ITEM (CSI) A part, assembly, installation, or production system with one or more critical characteristics that, if not conforming to the design data or quality requirements, would