Material / Stock Purge Request Forms

C

Cuchullainn

#1
Hi,
I am looking for a bit of help on managing Material / Stock purging when a non-conformance is identified.

I have being playing around with implementing a system using the task function in outlook but it's not easy.

Has anyone out there some examples of a purging system / form they have which captures these elements.

1. Identifies all areas / locations concerned.
2. A method to validate the task has been completed.
3. Checks that the requested qty's matches the purged qtys.

Thanks for you help


Jason
 
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Wes Bucey

Quite Involved in Discussions
#2
Just curious. How often do you have such a purge requirement in a given year? If there is more than one, I'd concentrate on root cause, corrective action, preventive action, and lots of FMEA (Failure Mode & Effects Analysis) long before I'd spend time and money on creating and printing forms to handle the "cleanup" required after nonconformances are detected.
 
J

jrubio

#3
Wes Bucey said:
Just curious. How often do you have such a purge requirement in a given year? If there is more than one, I'd concentrate on root cause, corrective action, preventive action, and lots of FMEA (Failure Mode & Effects Analysis) long before I'd spend time and money on creating and printing forms to handle the "cleanup" required after nonconformances are detected.
Other important fact to do what Wes mentioned is what is the feedback of the Customer?.
 
C

Cuchullainn

#4
Thanks for the response Wes.

I am trying to implement it for NCM received from our suppliers.

This purpose of this purge process would be to contain defective material supplied by our supplier immediately and minimize the impact to our production process. i.e. we have identified a supplier issue on our production floor which will be reported by the production staff but they currently do not contain the entire batch (check all areas) and the warehouse release more of the defective material to replenish the process.

I looking for a smart way to publish where (locations) this material is, have a deadline to purge the defective stock, & a system to validate that it was conducted correctly.
 

Wes Bucey

Quite Involved in Discussions
#5
Cuchullainn said:
Thanks for the response Wes.

I am trying to implement it for NCM received from our suppliers.

This purpose of this purge process would be to contain defective material supplied by our supplier immediately and minimize the impact to our production process. i.e. we have identified a supplier issue on our production floor which will be reported by the production staff but they currently do not contain the entire batch (check all areas) and the warehouse release more of the defective material to replenish the process.

I looking for a smart way to publish where (locations) this material is, have a deadline to purge the defective stock, & a system to validate that it was conducted correctly.
The typical process is not "purge," but ""quarantine" until absolute confirmation of defect.

Best practices include confirmation of acceptability of product BEFORE it ever leaves supplier's dock. There are various techniques and processes to do this - topic for a new thread after you do a search for the topic.

When it is a possibility or probability there may be nonconforming product in an incoming shipment, good practices include holding material in quarantine until a statistically valid sample is pulled and inspected for the probable nonconforming characteristics or features. This obviates necessity for searching out material distributed throughout production facilities. Customers need to give themselves sufficient lead time to do this inspection before the product is urgently needed on the production line. (This is still consistent with Just In Time systems, merely altering the JIT deadline from production date to inspection date.)

In almost every case, the best practice is to prevent nonconforming product from ever reaching the production floor and the suppliers have to be enlisted in the effort to achieve this goal.

If, in spite of all efforts to the contrary, there is still a probability of nonconforming product reaching the production floor, it is absolutely necessary to maintain strict lot control, never allowing product from one lot to mix with product from another lot. This may entail maintaining sequential bins and stock areas, still much more cost0effective than a helter-skelter search throughout a plant looking for suspect material for quarantine. This process of maintaining lot control has the added benefit of giving traceability to even recall finished product in the field which may have incorporated suspect material BEFORE any nonconformity was detected in production. The beauty of traceability is that you recall ONLY product whcih may contain suspect material, NOT ALL product.
 

Wes Bucey

Quite Involved in Discussions
#6
Cuchullainn said:
I looking for a smart way to publish where (locations) this material is, have a deadline to purge the defective stock, & a system to validate that it was conducted correctly.
It occurs to me the mistake proofing may be easier to maintain if you change the storage system rather than graft extra paperwork on a storage system which may not be as efficient or effective as it should be.


:topic: Just wanted to say I enjoy the story of the namesake of your screen name. Do you have any links to a version YOU like?
 
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