Nonconforming Product - Report for each product we find with a nonconformance?

[Rosana]

In production when the operator is making the product they find an average of 20 nonconforming products in a day. The operator puts all of these nonconforming products in a box labeled "Rejected Products". At the end of the week there is a person who reworks all these nonconforming products. Do I need to prepare a nonconforming report for each product we find with a nonconformance? Or can we prepare a weekly report with a list of all the part numbers of nonconforming products?


Rosana

 

[db]

Two thoughts

Rosana, there are two parts to your question. The standard answers both parts. The first is answered in 8.3, Control of nonconforming product. It sorta sounds like you meet a - c. Your bigger question is found in 8.5.2. Do you need to prepare a nonconforming report for each product? I don't know. I do wonder what happens from the time the nonconforming product is discovered until it is dispositioned. Is any being done (or can anything be done) to stop recurrence? Just reworking the product might not be enough. Are you finding the root cause?

 

[ralphsulser]

Another thought,
I would question use of some methods, such as...who else is notified or aware of the non-conformances,timeliness, and how is the info captured and analyzed..as mentioned for root cause, or pareto, and costs associated with not only the non-conformances, but the rework continuously. Material Review Board evaluations and dispositions.
But prevention is the key. If prevented, identification is not required.. I keep saying this but, oh well.

 

[BobD]

Not knowing your produt / assembly line leaves me at a slight disadvantage. Depending upon if you are finding defective "purchased" product or "in-house" mfg product you may want to record the defects at different time frames. There is no problem with recording purchased product defects weekly. However, in the case of "in-house" defects, why wait 1-week before addressing the problem. If you look at the defects daily, you may be able to stop anymore from occurring. It's always better to catch them early and correct the cause.

One suggestion of recording defects would be to use a matrix. This way you can categorize the type of defect against the P/N.
This would be a good tool to see what and where the main problems lie.

The bottom line is...the standard requires regular reporting. However you set it up is up to you. Just remember to keep reporting on the same time frame (IE. hourly, daily, wkly, mthly).

Hope I have been of some help.

 

[Rosana]

Thanks for all of the input. Today I had a meeting with the Production Manager and we will try to do this better. I prepared a corrective action to analyze the root cause and see how we can improve this process.

Rosana

 

[Sam]

"Do I need to prepare a nonconforming report for each product we find with a nonconformance?"
If the rework is part of the process you would not need to complete an individual NCR for each part.
If the nonconforming part comes from another process, then yes you would need an NCR.

"Or can we prepare a weekly report with a list of all the part numbers of nonconforming products?"

Acceptable method. Pareto the defects and use to stabilize or improve the process.

IMO of course.