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Risk of stopping your customer's line

Graciel

Involved In Discussions
#1
Hello, have you guys been in a situation where there is a rejected raw material detected during production, which wasn't detected at incoming inspection, because it is skipped lot. When you search your warehouse, there is only one batch of it, the "rejected" one. Since you have the risk of stopping the line, do you think best option is to warn already the customer? Thank you.
 
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Jen Kirley

Quality and Auditing Expert
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#2
Hello, have you guys been in a situation where there is a rejected raw material detected during production, which wasn't detected at incoming inspection, because it is skipped lot. When you search your warehouse, there is only one batch of it, the "rejected" one. Since you have the risk of stopping the line, do you think best option is to warn already the customer? Thank you.
Hello Graciel,

If I correctly understand it, this rejected raw material could result in the end product being nonconforming. If that is true, I would certainly expect the customer would want to be informed so they could also take action that would prevent nonconforming product from being delivered to the end customer. Is that what your customer agreement says?
 

Johnny Quality

Involved In Discussions
#3
Graciel,

The question you are asking comes under the general statement of "we have delivered the customer possible non-conforming product". My default reaction would be to tell the customer and swap the suspect stock as soon as possible. You'll only gain favour with your customer as long as this isn't a common event as it shows you have a reaction plan and that you act on it, if it becomes common then your customer will begin to think your quality business system(s) is/are not effective.
 

John C. Abnet

Teacher, sensei, kennari
#4
there is only one batch of it, the "rejected" one. Since you have the risk of stopping the line, do you think best option is to warn already the customer?
Good day @Graciel
This post raises a lot of questions...
1- What do CSR or other customer requirements (i..e customer issued supplier handbook), tell your organization to do?
2- What does your organization's internal escalation process lead to? (i.e. where is your leadership involvement? Why are you asking "us" and not
getting direction from your organization's leadership?)
3- Regardless of "1" and "2" above, IATF 16949 stipulates the following...
8.7.1.1 (also see 8.7.1.6...)
"...shall obtain customer concession or deviation permit prior to further processing whenever product or manufacturing process is different from that which is currently improved..."
NOTE: Not sure if you are speaking of your internal or customer when you refer to "risk of stopping the line" , but regardless, remember that a late or "missed" shipment is also a nonconformance.

So, the short answer is 'YES", but the question leads to the additional questions I have stated above.

Hope this helps.

Be well.
 

qualprod

Trusted Information Resource
#5
Hello, have you guys been in a situation where there is a rejected raw material detected during production, which wasn't detected at incoming inspection, because it is skipped lot. When you search your warehouse, there is only one batch of it, the "rejected" one. Since you have the risk of stopping the line, do you think best option is to warn already the customer? Thank you.
More information is needed from you to propose the answers.

If it was a skipped lot, I suppose as you said was "skipped", I think you mean that your inspection process
didn´t inspect such raw material, up to this point you can do something.
If it was skipped, how are you going to decrease the skipping? in the case that you don´t inspect at 100%.

Maybe you have a very relaxed criteria (maybe only to inspect at certain volume, weight, amount, quantity)
so it may be needed to "tight" the inspection criteria.
On the other hand, you could apply another "checking" before the production starts.
Also before product is shipped, you have the option to apply an additional "checking".
So evaluate what apply to you.
For the side of the customer, well, eventually will receive defective product, in this, case be aware of this
by communicating these events.
If neccesary, you have to be able, to do a recall of the product.

This is my response, if I understood well.

Regards
 
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