3. » Clearly identified using consistent identification
(tagging).
» Prevented from unintended use or installation
(containment).
• Establish a consistent identification process using
a Visual
• Management method.
• The achievement of customer expectations relies on a method to contain
defects (NONCONFORMING PRODUCT) within the manufacturing
process, and implement corrections to protect the next/downstream
customer.
4. COLOUR CODE IDENTIFICATION OF BIN
RED BIN FOR
REJECT PARTS
YELLOW BIN FOR
SUSPECTED PARTS
GREEN BIN FOR OK
PARTS
5. OK & NG SAMPLE DISPLAY FOR BETTER UNDERSTANDING
6. • Nonconforming product shall be prevented from unintended use
• or installation through containment.
•
• Leadership must develop, organize and maintain a system
• for control of nonconforming product.
• All nonconforming and suspect product shall be segregated.
•
• SEGREGATION AREAS:
• Segregation areas shall be foot printed or otherwise identified.
• Example: - Scrap bins
• - Rework Tables
• - Containment areas
• - Nonconforming material hold areas
7. • Nonconforming product shall be prevented from unintended use
or installation through containment.
• Leadership must develop, organize and maintain a system
for control of nonconforming product.
• All nonconforming and suspect product shall be segregated.
UNDERSTANDING THE DEFECT
• Clear understanding of the Standard and the Deviation
• Good visuals explaining the above.
BREAK POINT:
• Only give a break point after you understand the DEFECT and
have contained all nonconforming product.
REMEMBER:
Violating the BREAKPOINT is the biggest mistake you can make.
8. – For product containment issues, containers shall be identified:
• - Red = Nonconforming product
• - Yellow = Suspect product
• - Green = After breakpoint conforming product
– Containment activity and tasks must be customer approved with
– supporting documentation:
– - work instructions
– - referenced in control plan
– - operator training records
–
– Customer Engineering approval may be required.
– All Control Plan inspections and tests shall be performed; product
– removed from the approved process flow shall be reintroduced into
– the process stream at or prior to the point of removal.
–
9. • Containment Worksheet shall be used and completed to:
- Provide a systematic approach to containing all suspect product.
- Identify all areas to be checked for nonconforming product.
• Process & authority for releasing product out of rework, repair and
containment areas shall be defined.
• Follow a documented containment procedure to prevent identified
defects from flowing to the next customer.
• Containment procedure requirements:
― Define quality standards which are clear and measurable
― Document containment methods in standardized work (e.g. JES)
― Specify start/stop date on document (short term activity should
be as short as possible)
― Track and document results to verify effectiveness
(i.e. Temporary Verification Station)
― Initiate the problem solving process
10. • Assures all suspect and nonconforming
product is contained.
• Increases customer satisfaction and
communication.
• Reduces repetitive quality disruptions.
• Assures all issues are resolved with all
customer contacts:
• internal and external.
• Assures a systematic approach for all
issues.
CONTROL OF
NONCONFORMING PRODUCT
benifits
11. • Nonconforming product shall be:
– clearly identified using consistent identification (tagging).
– contained through the use of a Containment Worksheet.
– segregated in well identified areas.
– released using a defined process and authority.
– reintroduced into the process stream at or prior to the
– point of removal.
–
• Organization shall have a nonconformance alert and
• containment procedure that meets customers requirements
• (timeline, steps, communication, etc).
• Product containment issues shall be reviewed by Leadership.
CONTROL OF NONCONFORMING PRODUCT
SUMMARY
