Practical Way to raise NCR's in an Assembly Workshop

[QAMTY]

Hi everybody

Could you share a practical way to raise ncr´s in an assembly workshop

ISO 9001 2008, states that in order for the bad products do not arrive at client, an NCR should be raised, from then a disposition is needed, scrap, to repair, to be accepted for the client, etc.

But is not recommended to raise an NCR for everything, if it is a minor NC, maybe is not necessary to raise the ncr, but if it is a big or medium problem, for sure it is needed to raise the NCR.

From that a CAR is expected.

The point is how to put this in practice?, what criteria to follow in order to make this process easy and practical, that really adds value.

It may be, if the bad product is 3%, raise the RNc, other criteria if the cost of raw material falls in certain amount $$, raise the RNC, but doing it using such criteria is not so simple to be applied in all products.
Raisings NCRs for everything,additionally to perform CA´s, I think is wasting time and efforts.

What citeria do you use/follow to raise NCRS´s in your business?

Please share your comments.
Thanks

 

[DRAMMAN]

Well, first off do not focus on using ISO9001:2008 since it is obsolete. Go read ISO9001:2015.

I assume you are referring to documenting a Non-Conformance Report. ISO does not specifically state you must do this. Although you do need to prevent non-conformances from reaching customers. In a practical sense you are likely not going to record everything in an assembly process. As you stated you will not want to record every single instance of an operator experiencing a NC. Simple things will be fixed on the fly. Then you can have rules to document certain issues such as supplier defects or line-down situations.

 

[QAMTY]

Thanks Dramman

You are right, that´s the idea, minor nc´s, should be fixed on the fly.

The rules for certain issues is what is very important, that is what I´m looking for.
Do you have some rules to share?

Thank you

 

[Mark Meer]

We have slightly different systems depending on occurrence rates and activity involvement:
Frequent = Easy, little documentation
Infrequent/Involved = More detailed documentation

For example:
- Scrapped NC components: happens all the time.
-- For items where there is little value for us to track (e.g. simple screws/fasteners), people can just scrap these.
-- For higher-cost items (where we'd like to gather data on yield), there is a simple spreadsheet logging the quantities scrapped. It takes all of a few seconds to make an entry before scrapping the identified NC item.

- Reworked NC components: less frequent.
-- For this, we do want to gather data, the value being that it can be involved process, and data is needed to do cost-benefit.
-- Again, though, we don't want to make documentation burdensome, so a spreadsheet is used, with just a few more columns than the scrapped items.

As DRAMMAN suggests, you can make the rules, and I'd suggest the first step is to identify what data is of value to you.

If people fix things on the fly, and you've got controls to ensure that everything is conforming prior to delivery, AND you don't see yourself needing/wanting to analyze data regarding the occurrences of such events, then why burden yourself unnecessarily?

MM.

 

[DRAMMAN]

I think it is going to vary by company and what you are trying to accomplish. Many companies are going to have multiple systems to track non-conformances. When I worked at a large corporation we had many systems to document and track non-conformances with thousands of NC's being recorded every day. It is really going to be up to each organization to decide which non-conformances are of value to track. Some companies may elect to only track customer complaints. Others may track many types of non-conformances such as scrap, test failures, line defects, supplier defects, etc.

From an auditing perspective it would be up to your auditor to evaluate your NC system. As an example, if you were a 500 employee factory and said you do not need to track non-conformances that would likely be challenged.

Smaller organizations may have a simple spreadsheet or Access database to record and track NC's.

 

[ReworkIT]

The LEAN gods are rolling their collective eyes! Not recording instances of non-conforming product is ignoring a form of waste. Aren't you confusing the cost of the actual component - a fastener - with the (true) cost of getting it into the hands of the operator? Isn't is supposed to work? "Right First Time"? If you don't at least put an "X" on a tally sheet of defects, isn't that wrong? I don't know, but our LEAN champion would be getting excited over this one, even if ISO auditors don't.

 

[QAMTY]

Thanks to all.
Dramman.

what you or Mark Meer suggest it sound interesting.
If I can catch the concept is like this.

Lets say when we detect a nc, whatever minor or major, first to register it in an excel file but not to fill out an NCR format for every Nc unless its is medium or big the problem, only to fill it out where it is needed to define the disposition is it ok?
The idea it is that at certain intervals, we have to check the excel file trying to determine the total cost of reworks, scrap for improvements purposes.
is it ok the way I perceive it?.
In fact, I think I can include in my Non conformance procedure that at every month I have to check such file in looking for improvements.
This way I dont have to fill out a lot of NCR formats, thus not wasting time and efforts.

Could you share a template for this?

Thanks

 

[Pancho]

Hi QAMTY,

If you are in Monterrey, we'd be happy to show you our system for handling NCs. PM me if you'd like to do so.

 

[QAMTY]

Thanks Pancho

Yes I live in mty, I´ll contact you later to see how you manage this stuff.

Thank you very much