Method of Monitoring our Internally Produced Non-Conforming Products


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Good Morning all, I am currently looking for some way of monitoring our internally produced non-conforming products (We are a CNC machine shop). We currently use an excel macro'd sheet to record everything but the data is questionable and able to be manipulated by the person entering the data (approximately 15 lines per week)

Does anyone have any recommendations or suggestions as to a software/template that has been successfully used?


Fully vaccinated are you?
Do you have a reason as to why you think employees are changing data?


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Any person who enters data will enter what they want, no matter how sophisticated the system. Is there a specific problem you're trying to address? Do you have evidence that the data in the current spreadsheet is bad? What does customer feedback shows you? A little (or a lot) more information would be helpful.


What about password protect your excel spreadsheet and only have it accessible to authorized users, such as the NCR/CAR Coordinator?
I'd be interested in such a spreadsheet if you're willing to share. My company is running a homegrown green screen database that only allows for the reporting of scrap, so I need an excel-based log in the interim.

Dr. IJ Arora

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Kearnj, has offered an option. My simpler recommendation is to make your excel worksheet, macro controlled, so that once data is entered it can not be deleted or changed without reference to the authorized person, perhaps the QM.
I do keep a spreadsheet for this, it is not that the data can be "changed" as much as the data is subjective, based on the perspective of the person entering it. Our sheet allows entries by numerous people, since there are many places where this can occur, and I want to capture it at the source, or at least at the discovery. The waterjet operator may blame the issue on fixturing in the jet (it might have moved), or a bad dxf from engineering, or a clog in the abrasive line, while someone else may see a kerfing issue, or a material problem . I might see it as a lack of engineering/manufacturing review. There are numerous "causes" when it comes to scrap and rework, and much is in the eye of the beholder. Nailing down some hard and fast rules is the essence of a consistent data stream.


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It sounds like the data you are in doubt of is a recorded "cause" for a defect report. I suggest there is a mistake expecting someone on the floor observing a defective unit, to then supply a cause to it. As you point out, there are differing opinions. To me this means you should be collecting the data on the objective nature of the defects, and depending upon what the data show, focus your efforts on finding root conditions for prioritized defects.

Cari Spears

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The person reporting nonconforming product doesn't need to know the cause at the moment that is being reported. I'd record what is wrong, at what point you detected the nonconformity, any containment action, who reviewed and dispositioned it, and what that disposition was. Then, as a team, determine the cause - it might be very obvious, it might require root cause investigation.
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