Managing Non-Conformance
By
Lieutenant Colonel R Srinivas
Roll No: 24, 4th
Semester
MBA(FT)-2008-10
Non conformance -Definition
• An activity, attribute, or document, is said to be
non-conforming if it fails to comply with...
Non conformance
Major Minor
• Major nonconformance - A lack of an element,
procedure, or a non-fulfilled requirement, that puts
the process/system at ...
Distinction between Non-conforming and Defective
Non-conforming Defective
A unit or service is
non-conforming
when atleast...
Absence of a
Well defined
System
Hazards
(sooner/later)
Threaten
Outputs or
schedules
Decision on action is required urgen...
• For the quality manager
Commitment
Credibility
Trust
Visibility
Peace of Mind
Benefits of a systematic approach
• For the business as a whole
Understanding of requirements.
Identification of causes and
preventive measures.
Knowledge
Q...
Stages involved in this process are:
1. Discovery
2. Identification
3. Segregation
4. Analysis
5. Approval
6. Documentatio...
• Non conformance may be discovered at many
stages.
• An investigation should be made to make a
clear decision as to what ...
• NMR(Non Conforming Material Report)
It is a document or computer record raised to
record occurrence, define conditions, ...
Discovery
Information entered in the NMR during the
discovery stage includes:
1. Material number, issue and description
2....
Identification
• Upon discovery of the non-conforming material, it is
necessary that all such material is identified as no...
Segregation
• Materials are segregated from all other
materials until a decision has been made on
disposition.
• Such an a...
Analysis
There are 5 stages
• 1st
stage: To determine whether the item is truly non-
conforming, defective, or both.
• 2nd...
• 4th
stage: To determine what can be done with the items.
Major options available are:
->return to supplier
->sort, then ...
Approval
• It involves completing the NMR to indicate disposition,
liability and actions required which affected parties s...
Documentation
• As a result of analysis and approval of
disposition, liability and actions agreed,
documents are raised to...
Close out
• The quality function ensures that materials
are only used as approved on the NMR and
that follow-up actions fo...
Tracking
• Records of NMRs raised are maintained by the
quality function to determine whether the
actions taken are effect...
Controls
• Ensure that all occurrences are exposed when
they occur.
• Therefore, it is necessary to consider the
major sou...
• Some of the many sources of non-
conformance are:
Design
Manufacturing planning
Suppliers
Material supply
Transportation...
• Discovery of non-conformances will occur in
one of the four areas:
1. Incoming Inspection
2. In-process
3. Final test/in...
Incoming Inspection
• Purchased materials are inspected.
• Non-conformance is looked for on a sample basis,
generally on s...
• Another important aspect relating to vendor
non-conformance, is the need for the
vendor to identify clearly the cause an...
In-process
In-process problems should be addressed
on a high priority basis.
Non
Conformance
(in process
Stage)
Defect/fai...
Final test and inspection
• Handled in a uniform manner.
• It is conducted as specified.
• Non-conforming items should rec...
Customer Returns
• Sometimes handled by service department and
sometimes by quality function.
• Here, both corrective/prev...
Conclusion
In spite of measures taken in design, planning,
manufacturing and throughout the business, the
process “MANAGIN...
THANK YOU AND JAI HIND!
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Managing non conformance colonel sri(titto sunny)

  1. 1. Managing Non-Conformance By Lieutenant Colonel R Srinivas Roll No: 24, 4th Semester MBA(FT)-2008-10
  2. 2. Non conformance -Definition • An activity, attribute, or document, is said to be non-conforming if it fails to comply with established requirements, and may lead to a condition having an adverse effect on the environment, safety, security, health, operations, quality or reliability.
  3. 3. Non conformance Major Minor
  4. 4. • Major nonconformance - A lack of an element, procedure, or a non-fulfilled requirement, that puts the process/system at danger, and could lead to significant impact on ESS&H, operations, quality or reliability. • Minor nonconformance - An observed lapse in a program, process, procedure, or requirement, usually single incidents that do not have a significant impact on ESS&H, operations, quality or reliability.
  5. 5. Distinction between Non-conforming and Defective Non-conforming Defective A unit or service is non-conforming when atleast one quality characteristic causes a specified requirement not to be met. A unit or service is defective when atleast one quality characteristic causes a failure to satisfy an intended purpose.
  6. 6. Absence of a Well defined System Hazards (sooner/later) Threaten Outputs or schedules Decision on action is required urgently Quality Manager
  7. 7. • For the quality manager Commitment Credibility Trust Visibility Peace of Mind Benefits of a systematic approach
  8. 8. • For the business as a whole Understanding of requirements. Identification of causes and preventive measures. Knowledge Quality improvements Increased profitability
  9. 9. Stages involved in this process are: 1. Discovery 2. Identification 3. Segregation 4. Analysis 5. Approval 6. Documentation 7. Disposal 8. Closeout 9. Tracking Process for managing non- conformance
  10. 10. • Non conformance may be discovered at many stages. • An investigation should be made to make a clear decision as to what should be done with the items under consideration or what action should be taken to avoid recurrence
  11. 11. • NMR(Non Conforming Material Report) It is a document or computer record raised to record occurrence, define conditions, identify how to dispose of the items and giving reference to documents initiating further actions required.
  12. 12. Discovery Information entered in the NMR during the discovery stage includes: 1. Material number, issue and description 2. Specified and actual result 3. Quantity of the nonconforming items 4. Batch/order number 5. Originator’s name and the date raised.
  13. 13. Identification • Upon discovery of the non-conforming material, it is necessary that all such material is identified as non- conforming materials or “Do not use” material. • Commonly red labels or letterings are used in the following forms: Tote box label inserts Adhesive tapes Sign plates
  14. 14. Segregation • Materials are segregated from all other materials until a decision has been made on disposition. • Such an area is called quarantine area.
  15. 15. Analysis There are 5 stages • 1st stage: To determine whether the item is truly non- conforming, defective, or both. • 2nd stage: To determine the extent of non-conformance. ->The maximum deviation from specification. ->The quantity or rate of items non-conforming. • 3rd stage: To determine what effect the non-conformance will have on the function or saleability of the product.
  16. 16. • 4th stage: To determine what can be done with the items. Major options available are: ->return to supplier ->sort, then rework, repair or scrap. • 5th stage: To determine who is responsible for causing the non conformance or defect.
  17. 17. Approval • It involves completing the NMR to indicate disposition, liability and actions required which affected parties sign to signify their approval. • This may involve a meeting of nominated representatives. • Involves walking the NMR around to those concerned or it may be a single individual who completes the documents to record occurrence, disposition and liability.
  18. 18. Documentation • As a result of analysis and approval of disposition, liability and actions agreed, documents are raised to initiate actions.
  19. 19. Close out • The quality function ensures that materials are only used as approved on the NMR and that follow-up actions for correction or prevention are implemented. For rework or repair this may involve the re-inspection of the items.
  20. 20. Tracking • Records of NMRs raised are maintained by the quality function to determine whether the actions taken are effective in reducing the number of non-conformances.
  21. 21. Controls • Ensure that all occurrences are exposed when they occur. • Therefore, it is necessary to consider the major sources of non-conformances and the key areas of exposure.
  22. 22. • Some of the many sources of non- conformance are: Design Manufacturing planning Suppliers Material supply Transportation Customers Warehousing etc.
  23. 23. • Discovery of non-conformances will occur in one of the four areas: 1. Incoming Inspection 2. In-process 3. Final test/inspection 4. Customer returns
  24. 24. Incoming Inspection • Purchased materials are inspected. • Non-conformance is looked for on a sample basis, generally on selected key parameters or characteristics. • For this area to be effective, it is essential that all parameters or characteristics are inspected on the entire sample quantity.
  25. 25. • Another important aspect relating to vendor non-conformance, is the need for the vendor to identify clearly the cause and action being taken to prevent recurrence. • To trigger and track this activity, many companies issue a Corrective Action Request(CAR) form to the suppliers.
  26. 26. In-process In-process problems should be addressed on a high priority basis. Non Conformance (in process Stage) Defect/failure Hampers/ Prevents Further production
  27. 27. Final test and inspection • Handled in a uniform manner. • It is conducted as specified. • Non-conforming items should receive full review and approval. • The quality function handles such matters often with the support from specialist technical or engineering functions.
  28. 28. Customer Returns • Sometimes handled by service department and sometimes by quality function. • Here, both corrective/preventive actions and customer settlements and responses should be considered. • Even if the issue is handled by the quality function, full knowledge and approval of the sales function is necessary.
  29. 29. Conclusion In spite of measures taken in design, planning, manufacturing and throughout the business, the process “MANAGING OF NON CONFORMANCE”, is all about facing up to the fact that specifications or standards have not been achieved. If handled badly, all the earlier measures taken will count for little. But, if handled well, the process will serve as a foundation on which all other activities can depend and flourish.
  30. 30. THANK YOU AND JAI HIND!

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