Q
It sounds like it is more a matter of HOW you document. I wonder if, after a couple bent screws are found, that if should be reported to the inspector/auditor. They would then pass that information along to the QC Manager or other QC person of authority. It would be up to that person to make the decision as to HOW to document it.
If it is a very low value item like a screw, he/she may decide to have the processors keep a simple tally of how many bent screws show up each shift and do this over a period of time to determine how big of a problem it is. If he/she determines that it is a big problem, then they might take steps to fix the problem, either with increased raw materials inspections or by contacting the supplier.
If it is a very high value item or a low value item, but a very critical one (for instance a $0.50 bolt, but one that holds the engine in a car), then then he/she might decide to issue a CAR or approach the situation more aggressively.
Just my 2 cents.
QCDave
If it is a very low value item like a screw, he/she may decide to have the processors keep a simple tally of how many bent screws show up each shift and do this over a period of time to determine how big of a problem it is. If he/she determines that it is a big problem, then they might take steps to fix the problem, either with increased raw materials inspections or by contacting the supplier.
If it is a very high value item or a low value item, but a very critical one (for instance a $0.50 bolt, but one that holds the engine in a car), then then he/she might decide to issue a CAR or approach the situation more aggressively.
Just my 2 cents.
QCDave
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...but it is easy to fall into the trap of thinking that everything non-ideal must be documented...and clogging an otherwise good system with NVA or LVA work.
