Corrective Action for Operators Not Following Documentation

A

Andrews

#1
corrective action

During our last corrective action team meeting , we found that around 60% of the quality problems were due to the operators not inspecting the parts as per the control plan given to them. What should be done in such cases? Inspite of numerous training programmes and warnings, we found that this situation is not improving. any suggestions?
 
Elsmar Forum Sponsor
M

M Greenaway

#2
I suggest you do a '5 Why' analysis on the inspection process to determine root cause.

If the inspectors are just plain negligent (possible but doubtful) then you would need to take disciplinary action, however I would suspect that you find a problem somewhere with the system.

If on the other hand you actually want to improve quality try to determine the causes of the actual faults and eliminate them, as you cannot inspect quality into the product.
 
A

Andrews

#3
The quality problems could have been identified if the operator had checked the components at the frequency of 10 pieces / hour as required by the control plan.

In one case the operator had not taken out the end bits that was found in the production batch inspite of us providing a sensor that STOPS the machine if there is not sufficient material to feed the bar to the required length.
 

Mike S.

Happy to be Alive
Trusted Information Resource
#4
Andrews,

I don't know enough about the problem to comment in depth, but Martin's idea is a good one. I would also say you could try throwing the problem back at those believed to be "at fault". Tell them the problem, the consequences of the problem to the rest of the process or the customer or money/time lost or whatever, and then ask them how they propose to eliminate this problem. Sometimes this works and you find some solutions you would not have considered and you get more buy-in.
 
D

David Hartman

#6
Perhaps you need to go back to the operators and explain to them what you have observed, and ask them why they are not performing the inspections according to the control plan.

You may find such system issues as: Unrealistic production quotas that do not allow time for inspection, inefficient inspection methods/tooling, or any number of issues attributable to the system and not the workers.

I continue to believe that a worker will do the right things, if the system allows.;)
 
A

Al Dyer

#7
Sounds like root cause has not been adequately determined.

How about getting away from the operator for the moment and think about why training, write-ups, discipline have not worked?

Are instructions posted?
Have the instructions been tested for ease of use?
Is the level of supervision on the floor adequate?
Is final quality responsibility with manufacturing or quality?
Are there language or dialect problems?
Are there ongoing tests of operator capabilities?
Does management really care?
Are you using the correct tools to determine process capability?
Is the gage control system robust and proven?

ETC...

Just wanted to get the gist of my view across.
 
I

ISO Cheesy

#9
Sounds like this is a recurring issue if I’m reading it right. What did your follow up from previous CARs tell you? Was the training/ warnings prior corrective action? Sounds like you need to dig a bit deeper. To Al Dyer’s point:

Why people don’t perform:
Improper Instructions
Improper Tools
Improper Training
Lost Expectations

Now I have a question on corrective action and the ISO2000 standard.” A documented procedure shall be established to define req. for…..Para e) records of the results of action taken (see 4.2.4)”

Does this mean that the follow up is now the quality record? I have a separate report for follow up to try to stay away from the check box of “effective”
 
Last edited by a moderator:
A

alexfox

#10
Review your CAR,the corrective action is available and which be performed fully.
The corrective action meeting is day-by-day,operators have enough training time?and what is the trend?
 
Thread starter Similar threads Forum Replies Date
D Corrective Action Timing - IATF CB Deadline IATF 16949 - Automotive Quality Systems Standard 2
R AS 9100D - Containment and Corrective action AS9100, IAQG, NADCAP and Aerospace related Standards and Requirements 3
P Customer Corrective Action Requests in OASIS? AS9100, IAQG, NADCAP and Aerospace related Standards and Requirements 4
C Corrective action for failure in documents control ISO 9000, ISO 9001, and ISO 9004 Quality Management Systems Standards 10
G Assignable cause/corrective action list for SPC Software Statistical Analysis Tools, Techniques and SPC 3
S Can we provide training plan as corrective action for IATF 16949 Non conformity? IATF 16949 - Automotive Quality Systems Standard 9
P Corrective Action Response for Missed bumps on brake press Manufacturing and Related Processes 2
B Stakeholder Initiated Corrective and Preventive Action Misc. Quality Assurance and Business Systems Related Topics 5
B Corrective and Preventive Action (CAPA) A Key Process of the Quality Management System Dec 17... Training - Internal, External, Online and Distance Learning 0
I When exactly can a corrective action be closed? Nonconformance and Corrective Action 3
L What to do if a Corrective Action requires several extensions Nonconformance and Corrective Action 7
qualprod Best criteria to measure Corrective Action effectiveness - Poor Maintenance ISO 9000, ISO 9001, and ISO 9004 Quality Management Systems Standards 10
Ashok sunder Is it possible to reduce Risk likelihood and impact Post control Ranking after corrective action taken for risk? FMEA and Control Plans 1
E CAR (Corrective Action Report) with questionable Root Cause ISO 9000, ISO 9001, and ISO 9004 Quality Management Systems Standards 14
B How to reply NCR on ineffectiveness of corrective action during IATF external audit? This is repeated issue whereby some mistake was done. IATF 16949 - Automotive Quality Systems Standard 7
I AS9100D Non-conformance for 10.2.1 b 2 and 10.2.1. b 3 e and f - Corrective Action AS9100, IAQG, NADCAP and Aerospace related Standards and Requirements 10
I Corrective Action Tracking for Product and Process in the same system? ISO 9000, ISO 9001, and ISO 9004 Quality Management Systems Standards 6
Ashok sunder Is it possible to reduce FMEA Occurrence and Detection Ranking after corrective action taken for customer complaints? FMEA and Control Plans 6
R CIP (Corrective Action) requirements - ISO 9001 clause 10.2 ISO 9000, ISO 9001, and ISO 9004 Quality Management Systems Standards 10
E CAR (Corrective Action Request) Due Dates ISO 9000, ISO 9001, and ISO 9004 Quality Management Systems Standards 17
E Corrective Action or Customer Complaint ISO 9000, ISO 9001, and ISO 9004 Quality Management Systems Standards 16
J If Corrective and Preventive Action were truly Effective IATF 16949 - Automotive Quality Systems Standard 3
qualprod Is a Corrective Action Expected if a Quality Objective is not in compliance? ISO 9000, ISO 9001, and ISO 9004 Quality Management Systems Standards 38
M Corrective Action Effectiveness Nonconformance and Corrective Action 5
P Documentation for correction, corrective action, mini CAPA Nonconformance and Corrective Action 9
P Interesting Discussion Addressing Human Factors in Corrective Action AS9100, IAQG, NADCAP and Aerospace related Standards and Requirements 23
S Formal written response to a corrective action? Nonconformance and Corrective Action 9
Q AS9100D Corrective Action Procedure needed Document Control Systems, Procedures, Forms and Templates 1
S Corrective Action from Internal Audits not performed ISO 9000, ISO 9001, and ISO 9004 Quality Management Systems Standards 24
J We don't have enough Corrective action entries AS9100, IAQG, NADCAP and Aerospace related Standards and Requirements 10
T Timely Closure and "Ongoing" Corrective Action Nonconformance and Corrective Action 15
P Examples of Nonconformance, Corrective Action Requests, and Root Cause Analysis Nonconformance and Corrective Action 2
S How to Politely Close out a Nuisance Customer Corrective Action? Nonconformance and Corrective Action 11
R How many Corrective Action Request can be Issued by DCMA for a single issue? Nonconformance and Corrective Action 2
MarilynJ6354 Missing Corrective Actions - Workforce does not trigger corrective action requests General Auditing Discussions 6
J When to Initiate a CAR (Corrective Action Request) ISO 9000, ISO 9001, and ISO 9004 Quality Management Systems Standards 6
A Corrective Action Software Recommendations Nonconformance and Corrective Action 4
S SCAR (Supplier Corrective Action Request) Timeliness & Issuance Supplier Quality Assurance and other Supplier Issues 3
Fender1 Customer specified Item Defect Corrective Action Responsibility Customer Complaints 18
Q Corrective Action - Assigning KPIs to Non-Guilty Processes ISO 9000, ISO 9001, and ISO 9004 Quality Management Systems Standards 5
5 Expediting Internal Corrective Action Requests (CAR) Closures Nonconformance and Corrective Action 3
J Corrective Action for External Audit NCMR (Procedure Not Followed) ISO 9000, ISO 9001, and ISO 9004 Quality Management Systems Standards 6
J ISO 9001:2015 Clause10.2 Nonconformity and Corrective Action - Deal with Consequences ISO 9000, ISO 9001, and ISO 9004 Quality Management Systems Standards 2
T ISO 9001:2015 Clause 9.2.2 Internal Audit - Corrective Action Report Format ISO 9000, ISO 9001, and ISO 9004 Quality Management Systems Standards 7
C Recurring Nonconformance - Missing Deadline for Closing a Corrective Action Problem Solving, Root Cause Fault and Failure Analysis 14
D Seeking Corrective Action Process Examples Nonconformance and Corrective Action 3
V Corrective Action for a scenario where Assignable Cause is not confirmed Nonconformance and Corrective Action 4
U Who is responsible to initiate a Supplier Corrective Action? Supplier Quality Assurance and other Supplier Issues 13
K Suppliers not responding to Supplier Corrective Action Requests (SCAR) Supplier Quality Assurance and other Supplier Issues 12
Q How to Report Non-compliance and Corrective Action to EU Member States EU Medical Device Regulations 5

Similar threads

Top Bottom