We don't have enough Corrective action entries

Jcornett344

Starting to get Involved
#1
I work in a small AS9100D certified machine shop/plastic production shop, and our work is pretty consistent and basic. We don't encounter too many problems and things generally run smoothly.

Because of this, we do not have many entries into our corrective action system (27 over the course of 18 months, and none in the last 5 months)

Am I correct in assuming that regardless of whether or not we're encountering issues that need addressing, that an auditor will not like seeing the lack of entries in the CA system?

Any advice on how to identify possible entries, for the sake of appealing to our auditor?
 
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Randy

Super Moderator
#2
It doesn't matter what an auditor likes, I'm an auditor, and I'm not part of the equation.

Do what you're supposed to do and that's if you identify a problem, document and correct as required....And don't be creative for the sake of pleasing a stinking auditor!
 

qualprod

Trusted Information Resource
#4
As you say "run smoothly" why you have to worry about.
That it means , is ok.
The problem is if your auditor finds complaints, non conformance products, or in general no compliment to the system and you don't have CAs.
 

Sidney Vianna

Post Responsibly
Staff member
Admin
#5
Any advice on how to identify possible entries, for the sake of appealing to our auditor?
As already mentioned, no system should be designed to please an outside auditor. You are the one who has to live with the system day in, day out.
Do you have any data on product rework, repair, scrap or product returns and customer complaints?

Risk-based auditing for system performance is how auditing should be done. But that requires reliable performance data. Something that some small companies can’t seem to grasp.
 

Jcornett344

Starting to get Involved
#6
I suppose I'm an over-thinker and assume that a lack of activity in the "improvement" area implies to an auditor that we are possibly hiding any nonconformances from them.

From what everyone is saying, I am getting the impression that this is not the case. And that maybe given that we are a small company, a consistent flow of corrective actions isn't necessarily a red flag. However, if the auditor did his normal digging and found reported noncomformances in say, internal audits or customer complaints, that had no corresponding corrective action, then that would qualify as an NC during our audit.

I apologize if my inquiries come off nonsensical. I was thrown in this position without much notice or training. I am trying to do the best job I can and maintain the confidence of management.
 
#7
I suppose I'm an over-thinker and assume that a lack of activity in the "improvement" area implies to an auditor that we are possibly hiding any nonconformances from them.

From what everyone is saying, I am getting the impression that this is not the case. And that maybe given that we are a small company, a consistent flow of corrective actions isn't necessarily a red flag. However, if the auditor did his normal digging and found reported noncomformances in say, internal audits or customer complaints, that had no corresponding corrective action, then that would qualify as an NC during our audit.

I apologize if my inquiries come off nonsensical. I was thrown in this position without much notice or training. I am trying to do the best job I can and maintain the confidence of management.
There ya go again, over-thinking...:lol:;)

Your best bet is to do a deep dive internal audit. CB auditors are gifted in any way. So, audit your own processes and confirm, as you should, that your CAR system is working as planned...
 

Randy

Super Moderator
#8
I suppose I'm an over-thinker and assume that a lack of activity in the "improvement" area implies to an auditor that we are possibly hiding any nonconformances from them.

From what everyone is saying, I am getting the impression that this is not the case. And that maybe given that we are a small company, a consistent flow of corrective actions isn't necessarily a red flag. However, if the auditor did his normal digging and found reported noncomformances in say, internal audits or customer complaints, that had no corresponding corrective action, then that would qualify as an NC during our audit.

I apologize if my inquiries come off nonsensical. I was thrown in this position without much notice or training. I am trying to do the best job I can and maintain the confidence of management.
I'd flat guarantee, without setting foot in your building, that you have 100 improvements happening today that you just don't recognize as such. Everyone is guilty because they think improvement has to involve tons on money, hundreds of people jumping through hoops and up their buts, plans, metrics, goobles of data and all kinds of crazy action when in fact doing a simple document revision is an improvement...It can be that simple.

I do absolutely nothing but audit as I said earlier and many times I see unrecognized and unclaimed improvements as soon as I pull into a parking lot or walk in the front door.
 

Pancho

wikineer
Super Moderator
#10
I'd flat guarantee, without setting foot in your building, that you have 100 improvements happening today that you just don't recognize as such. Everyone is guilty because they think improvement has to involve tons on money, hundreds of people jumping through hoops and up their buts, plans, metrics, goobles of data and all kinds of crazy action when in fact doing a simple document revision is an improvement...It can be that simple.
Agree 100%, Randy. And there's likely another hundred improvements being missed if folks don't know how to log an action request, let alone modify a process.

Train and empower them to do both. Small improvements add up over time.
 
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