Nonconforming & Corrective & Preventive Action

[hokieman]

I know this sounds intermediate But can someone explain or refer me to a spot in the cove which explains a step by step approach to how a Nonconforming Material Report & CAR/PAR Requests should track through a Mfg. facility. I just got my first NCR this morning and want to make sure it is handled correctly.

 

[Al Dyer]

Good question!


See here as a start

(broken link removed)

Al...

 

[Jim Wynne]

I know this sounds intermediate But can someone explain or refer me to a spot in the cove which explains a step by step approach to how a Nonconforming Material Report & CAR/PAR Requests should track through a Mfg. facility. I just got my first NCR this morning and want to make sure it is handled correctly.

Why not tell us the nature of the NCR in question? We can give better advice if we have the details.

 

[CarolX]

hokieman,
Look over the board that is dedicated to this subject. https://elsmar.com/elsmarqualityforum/forumdisplay.php?f=40
Additionally, scroll down to the bottom of this page for links to similar threads.

 

[hokieman]

This NCR was a simple one really, however it is still my first. The product in question was produced by a incorrect CNC program. The parts(s) (qty of 30 ea.) The drawing actually had two different dimensions. Our Engineering & Inspection group assumed the wrong dimension to be the correct one. The project mgr was out of town. I know, big breakdown in the system! We basically just need to fix the CNC program with a very minor correction to ensure this does not happen again.

 

[Rachel]

This NCR was a simple one really, however it is still my first. The product in question was produced by a incorrect CNC program. The parts(s) (qty of 30 ea.) The drawing actually had two different dimensions. Our Engineering & Inspection group assumed the wrong dimension to be the correct one. The project mgr was out of town. I know, big breakdown in the system! We basically just need to fix the CNC program with a very minor correction to ensure this does not happen again.

...I'd also look at the communication breakdown. The CNC program was wrong, yeah, but it was wrong because of a miscommunication on the drawing. Who signed off the drawing? Is there a change control/approval process for that?

Also - the project manager was out of town - stuff like that is bound to happen. What is your mechanism for delegation and dealing with absences?...the working world can't stop because one person is MIA.

Just some food for thought. The program fix , IMO, is your immediate corrective action - that takes care of this problem in the here-and-now. (A drawing revision is probably in order as well.) What are you going to do, though, to make sure a similar issue doesn't occur on another project with another part and project manager?

Not meaning to sound snooty - just stuff I've learned from managing our CAR system for the last 18 months or so.

Best of luck. The thing is - if you band-aid the issue, it'll go away quickly but come back in numbers. If you fix the nonconformance properly and thoroughly, it'll take a while longer - but with no recurrence. (Or little recurrence - come on, we're human!)

Cheers,
-R.

 

[Jim Wynne]

This NCR was a simple one really, however it is still my first. The product in question was produced by a incorrect CNC program.

No, the program did what it was told to do. Computers are like that.

The drawing actually had two different dimensions. Our Engineering & Inspection group assumed the wrong dimension to be the correct one.

There's your answer. If the specifications are ambiguous, someone needs to stop and go back to the source and get clarification. You need something in your system that requires documented correction before programming.

The project mgr was out of town. I know, big breakdown in the system! We basically just need to fix the CNC program with a very minor correction to ensure this does not happen again.

But unless you fix the system, it will happen again.

 

[michelle8075]

Best advice from me, is to insure that you are "Managing the Inferfaces" between each of the department's responsible. Pretty much on the same track as what the others posted, ensure that your corrective action response figures out how this sort of "break down" between departments doesn't happen again.

 

[hokieman]

Please Elaborate!

No, the program did what it was told to do. Computers are like that.

You are correct in what you are saying, as I stated earlier the program was incorrect.

 

[Jim Wynne]

No, the program did what it was told to do. Computers are like that.

You are correct in what you are saying, as I stated earlier the program was incorrect.

If I understand the situation correctly, the program was not incorrect. There was a decision made regarding an ambiguous specification, and the machine was programmed accordingly. The person programming the machine did so correctly and the machine followed the programmed instructions correctly. There was no problem with the program. In order to fix the immediate problem, the program has to be updated with the correct specifications.

Ask a group of people if they agree with this statement: "Computers never make mistakes." The great majority of people will disagree, some of them vehemently. The statement is true, however. All "computer errors" are ascribable to human error. To blame a computer for an input error is like blaming a filing cabinet when a document you're looking for has been misfiled.