1. Steps for product/material nonconformance:
Problems
Stop current process, sort and containment/ quarantine/ segregate nonconformances
Activation of Materials Control Plan (responsibilities defined, process outlined, etc.)
Classify the defect seriousness: major A, major B, minor, incidental
Generate non- conformity report (NCR)
Detected by production team.
Document the finding.
Determine impact (one item, lots, shipped or unshipped, etc.)
If from supplier, contact supplier with details, extent, disposition required (return, scrap, etc.), refund status, and supplier replace or rework
Update Material Receiving Report (MRR)
Detected by supply receipt
Evaluate continued use of supplier
Determine and address root cause(s) (initiate recurrence control)
Get additional details: type and length of use, etc.
Yes
Valid non-conformity? (i.e, not a learning curve)
Reported by customer (complaints, returns, etc.)
Make a feedback log entry
Analyze the problem(s)
Validate rework
Rework
Material Review Board (MRB)
Disposition:
Update customer with status.
Use As-Is No
Use as-is.
Initiate waiver (if reqd)
Assign
corrective actions:
Re-use portion of an assembly
Scrap
Continuous improvement
Initiate/update preventive actions to prevent future occurrences.
Landfill (last resort!)
Initiate Corrective Action Requests (CAR)
Close-out NCR and update log.
Recycle facility
Validate all actions and solutions.
grind and reuse raw material
Corrective Action Board (CAB): review CAR