Corrective Action Verification for Low Volume Production

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Path of Totality

#1
I have moved from an Automotive industry to Non-Automotive where we make parts for the Military and Medical fields. The volume is low but with a high dollar amount so the "luxury" of running trials and samples to confirm a potential corrective action is well.....zero. I am sure that my boss and the company will not let me build and trash a $12,000 part and since on some parts we make 3-5 pieces a month I would greatly hinder production. That said, how do you verify corrective actions without taking a year to do it. Where I used to work we made suspension parts and would produce 8,000 - 10,000 pcs per day on one part number alone. The parts were cheap and I could have statistical data inside of a week which would cover all shifts, lot numbers etc. To add to the problem, I have a few customers that don't really understand the concepts of an 8D so they don't understand why I can't have one done in a week. Anybody else in the same boat?
 
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#2
Re: CA Verification for Low Volume Production

I am in a similar situation here, our volume is even lower than what you mention. In several instances, it takes several months before we can perform the verification of effectiveness for our CARs. We implement the CA as soon as practically possible, but the effectiveness verification remains open until we can verify appropriately.
 
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Path of Totality

#4
Well, after some more thought and a couple various discussions on this sight the plan is as follows:

Communicate with the customer - novel idea huh!

I am in no way going to be able to close corrective actions due to the volume of parts we make in a 2-3 week time frame so, we will certainly take care of steps 1-3 in 24 hours but the rest will just have to happen based on available defective part and releases. I did this yesterday with a customer in California and after about 20 minutes of "debate" they conceded. My closing statement was that it would be "a diservice to the customer and my company to just fill out a piece of paper so a action item could be closed. It defeats the purpose of the Corrective Action methodologies"
 
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