This document discusses the control of nonconforming products. It emphasizes clearly identifying nonconforming products using consistent tags (e.g. red, yellow, green bins). Nonconforming products must be prevented from unintended use through containment, which includes segregating products and using a containment worksheet to identify all suspect products. Leadership must develop a system to control nonconforming products, and all containment activities must be approved by the customer.

2. PRESENTATION
CONTROL OF
NON-CONFORMING
PRODUCTS
Identification,Containment and
Communication
PRESENTED BY :- Dalveer Singh
Date of Presenting :- 06.08.13

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