It is essential to have a Nonconforming Material Process to manage your nonconforming materials (NCM), and prevent them from being processed or shipped to customers.
Some of the things to consider when developing and implementing a Nonconforming Material Process is but not limited to.
- Incoming Inspection and Defects
- Defective equipment in production
- Containment of finished products
- Containment of parts found in production
- Returning Material
- Initiate internal problem solving activity or an 8D request to supplier
- Material review
The Nonconforming Material Process needs to cover all aspects of what needs to happen when Nonconforming Material is detected. Everything from initial containment to what is done to avoid reoccurrence needs to be included in the process.
Typical Issues without Nonconforming Material Process
If an organisation don’t have an effective Nonconforming Material Process, the often have problems with following issues.
- Defective parts get used in production
- Defective material from supplier cannot be returned, as there is no proper agreement in place how to deal with this.
- Issues keep reoccurring due to insufficient or lack of correct problem solving
Implementing a Nonconforming Material Process
If you want to implement a Nonconforming Material Process or improve an existing one, then one option could be to use a quality consultant from EQMS and take advantage of the experience they have in that area. Alternatively if you want to take the task on yourself, splitting it up in below five steps will get you started.
- Identify Non-conformance: What is a non-conformance, what was received compared to what was expected. It is very important to identify and agree what the spec or requirement is, as there otherwise will be different perceptions of what a defect is. This is important internally, but also with suppliers to avoid long discussions when returning material.
- Containment: How do you contain the problem and avoid it from getting worse. For example, sort stock to be able to keep running without risk of defective parts in production.
- What to do with the NCM: Decide what need to happen with the nonconforming products or material. For example rework the parts, scrap them, or use them under a concession.
- Perform the Task: Organise and perform the task agreed in previous step.
- Corrective Action: The last step is to prevent the issue from happening again. This requires identifying the underlying root cause for the issue and eliminating it. Failure to do proper problem solving will result in reoccurrence of the problem.
If you are interested in implementing or improving your Nonconforming Material Process, then we offer quality consulting to help with the development, implementation and training.
Alternatively you can continue to our quality training page for an overview of training we provide.Go to Quality Training