To establish a Procedure for handling the nonconforming product situations at all stages of production, rejection received from customer and to decide the disposition actions to ensure that only conforming
products or products released under authorized concessions are released for further production . This procedure also specifies the system for controlling the nonconformance at each stage.
PROCEDURE :
Any deviation with respect to control plan / specification / work instruction /drawing etc. shall be treated as the non conformance and is applicable to incoming , inprocess and final stages and products returned by customer.
Identification and communication authority and related Quality record of non conforming products at all stage is as described in following table.
Sr. No. STAGES IDENTIFIED COMMUNICATE REF. RECORD
1 Incoming inspection QA Inspector Purchase, stores, QA head Inspection report
2 In-process Inspection QA inspector & shift coordinator Production, Purchase, Tool room QA Head Rejection record
3 Final inspection QA Dock Auditor Production, Dispatch ,QA Head Dock Audit report
4 Customer return Store head Production , QA head Customer return record
Monday, November 8, 2010
Incoming stg - NC product handling
All incoming nonconforming material / suspect material shall be identified by inspector QA ( incoming inspection ) putting a tag shall represent this.
The tag shall have all the cross references with respect to the sub contractor / customer, inspector’s identification.
The stage shall have all the cross – references with respect to the subcontractor / customer inspector’s identification .
These nonconforming product/ suspect materials shall be reviewed by QA. Head to take disposition actions once in day. The disposition action taken may be to rework, accept under deviation or to reject. In case of disposition action is to accept under deviation , it shall be approved by Plant In-charge.
Whenever , the decision taken is to rework the material, a rework plan shall be involved. At this stage a tag “ rework material “ shall identified the material . After rework the material shall re inspected as per the respective control plan.
When the decision taken is to “ accept’s it is “ then the deviation form shall be raised by concerned department head and approved by Plant In-charge.
When the decision taken is to reject a lot the “ rejected Material “ tag shall be put and returned to stores. In case , where decision taken is to scrap the material, is same shall be done at our premises.
In case of any non conformance observed for customer supplied raw material, the same shall be communicated to the customer and after receipt of feed back from customer, necessary disposition action shall be taken . This shall be the responsibility of Materials Head.
The tag shall have all the cross references with respect to the sub contractor / customer, inspector’s identification.
The stage shall have all the cross – references with respect to the subcontractor / customer inspector’s identification .
These nonconforming product/ suspect materials shall be reviewed by QA. Head to take disposition actions once in day. The disposition action taken may be to rework, accept under deviation or to reject. In case of disposition action is to accept under deviation , it shall be approved by Plant In-charge.
Whenever , the decision taken is to rework the material, a rework plan shall be involved. At this stage a tag “ rework material “ shall identified the material . After rework the material shall re inspected as per the respective control plan.
When the decision taken is to “ accept’s it is “ then the deviation form shall be raised by concerned department head and approved by Plant In-charge.
When the decision taken is to reject a lot the “ rejected Material “ tag shall be put and returned to stores. In case , where decision taken is to scrap the material, is same shall be done at our premises.
In case of any non conformance observed for customer supplied raw material, the same shall be communicated to the customer and after receipt of feed back from customer, necessary disposition action shall be taken . This shall be the responsibility of Materials Head.
Inprocess stg - NC product handling
All in-process nonconforming products shall be identified by inspector QA ( in-process inspection ) / Shift coordinator. Putting tag shall represent this. This tag shall have all the cross references with reference to operation no., parameter, GRIR no. in remarks ( if the nonconformance is due to subcontracted item ) ‘, shift details of non conformance and person’s ( identifying the non conformance and persons ( identifying the non conformance product ) identification.
These non conforming product / suspect material shall be reviewed by QA. Head or prod. Head daily and its corrective & preventive action plan shall be drawn in the weekly Quality review meeting.
Whenever, the decision taken is to rework the material shall be identified tag “ Rework material “ and rework plan will be involved and approved by QA Head. this shall include the specific instruction to be followed during rework.
If the decision taken is to rework or scrapped, the material produced from the previous frequency of inspection / production to the latest inspection, the material shall be segregated taken accordingly. This segregation shall be the responsibility of shift coordinator and the QA inspector.
All the non conformance identified during production shall be logged in the register.
All the rejected material shall be returned to stores by shift coordinator.
These non conforming product / suspect material shall be reviewed by QA. Head or prod. Head daily and its corrective & preventive action plan shall be drawn in the weekly Quality review meeting.
Whenever, the decision taken is to rework the material shall be identified tag “ Rework material “ and rework plan will be involved and approved by QA Head. this shall include the specific instruction to be followed during rework.
If the decision taken is to rework or scrapped, the material produced from the previous frequency of inspection / production to the latest inspection, the material shall be segregated taken accordingly. This segregation shall be the responsibility of shift coordinator and the QA inspector.
All the non conformance identified during production shall be logged in the register.
All the rejected material shall be returned to stores by shift coordinator.
Final stg - NC product handling
All the non conforming material during final inspection stage shall be identified by Dock auditor ( final inspection ). This shall be represented by putting a tag.
The tag shall have all the cross-references with respect to Part No. , part description, Nonconforming parameter and the person’s identification.
These non conforming products / suspect materials shall be reviewed by QA Engineer as and when it occurs and feedback given to QA Head.
Nonconforming lot shall be segregated and then only the material shall be grouped as “ok” “ rework ” or “ scrap ” Segregation shall be the carried out by Inspector QA.
Whenever the decision taken is to “ scrap “ the nonconforming material it shall be returned to the stores, (this shall be done immediately after the nonconforming products have been declared scrap) . This shall be done by QA Head.
Nonconformance at in-process stage and final inspection stage shall be discussed in weekly quality review meetings. During the meeting the cause of nonconformance shall be found out and a decision on remedial action taken. Then the disposition action of the nonconformance item shall be decided. The decision of member shall be recorded in the respective log register.
For rework items, if contractually required the actual condition and action plan proposed shall be communicated to customer prior to its implementation through QA Head, if approve by customer , the rework shall be carried out by Production department to correct the nonconformance observed as per the rework plan. The reworked item shall be re offered to stage / final inspection and the results verified.
The tag shall have all the cross-references with respect to Part No. , part description, Nonconforming parameter and the person’s identification.
These non conforming products / suspect materials shall be reviewed by QA Engineer as and when it occurs and feedback given to QA Head.
Nonconforming lot shall be segregated and then only the material shall be grouped as “ok” “ rework ” or “ scrap ” Segregation shall be the carried out by Inspector QA.
Whenever the decision taken is to “ scrap “ the nonconforming material it shall be returned to the stores, (this shall be done immediately after the nonconforming products have been declared scrap) . This shall be done by QA Head.
Nonconformance at in-process stage and final inspection stage shall be discussed in weekly quality review meetings. During the meeting the cause of nonconformance shall be found out and a decision on remedial action taken. Then the disposition action of the nonconformance item shall be decided. The decision of member shall be recorded in the respective log register.
For rework items, if contractually required the actual condition and action plan proposed shall be communicated to customer prior to its implementation through QA Head, if approve by customer , the rework shall be carried out by Production department to correct the nonconformance observed as per the rework plan. The reworked item shall be re offered to stage / final inspection and the results verified.
Customer return material
REJECTION MATERIAL RETURNED BY THE CUSTOMER SHALL BE DEALT AS FOLLOW ( CUSTOMER RETURNED MATERIAL ANALYSIS )
The Store department shall prepare GRN for customer rejection material ( this shall be done for only those material which are not customer supplied ). He shall maintain a record of this stating customer’s GRN no, the cause of rejection.
This shall be handed over to QA along with the cause of rejection.
A tag stating the part no. part description and, nonconforming parameter shall identify customer rejection material ( non-conformance )
At this stage 100% segregation will be done for the defect for which it has been rejected and the procedure on final inspection stage material shall apply.
DISPOSAL OF NC :
Products which are scrapped are to be immediately kept in area for scrap by shift co-operator in consultation with QA Head. In absence of QA Head it shall be given to Production head.
Components, which can be reworked, QA Head shall give proper rework instruction along with identified responsible person.
QA Head shall ensure approval from customer for rework on exterior of product and shall record it.
If product are process defers from PPAP approval QA Head shall take written authorization from customer VQA and shall keep record of it. It will be recorded in the following way . Date, previous process specification, written authorization details given by, customer and written authorization details given by, customer and written authorization date, aspiration date & Qty authorized . The batches those are sent under customer authorization, is identified suitably ( i.e. the details of concession , approval
ref. Approved as, etc. )
QA Head has authority to dispose off the non – conforming ( scrapped ) product.
Corrective and preventive action shall be taken to eliminate the cause of actual or potential nonconformity ‘s depending upon a degree appropriate to the magnitude of the problem and commensurate with the risks encountered.
QA Head shall prepare the summary status on all non conformance, the action taken their effectiveness and same shall be reviewed in the management review meeting.
The Store department shall prepare GRN for customer rejection material ( this shall be done for only those material which are not customer supplied ). He shall maintain a record of this stating customer’s GRN no, the cause of rejection.
This shall be handed over to QA along with the cause of rejection.
A tag stating the part no. part description and, nonconforming parameter shall identify customer rejection material ( non-conformance )
At this stage 100% segregation will be done for the defect for which it has been rejected and the procedure on final inspection stage material shall apply.
DISPOSAL OF NC :
Products which are scrapped are to be immediately kept in area for scrap by shift co-operator in consultation with QA Head. In absence of QA Head it shall be given to Production head.
Components, which can be reworked, QA Head shall give proper rework instruction along with identified responsible person.
QA Head shall ensure approval from customer for rework on exterior of product and shall record it.
If product are process defers from PPAP approval QA Head shall take written authorization from customer VQA and shall keep record of it. It will be recorded in the following way . Date, previous process specification, written authorization details given by, customer and written authorization details given by, customer and written authorization date, aspiration date & Qty authorized . The batches those are sent under customer authorization, is identified suitably ( i.e. the details of concession , approval
ref. Approved as, etc. )
QA Head has authority to dispose off the non – conforming ( scrapped ) product.
Corrective and preventive action shall be taken to eliminate the cause of actual or potential nonconformity ‘s depending upon a degree appropriate to the magnitude of the problem and commensurate with the risks encountered.
QA Head shall prepare the summary status on all non conformance, the action taken their effectiveness and same shall be reviewed in the management review meeting.
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