The following document templates (tool kits) are provided totally complimentary, free of charge to use as a starting point for Process of Control Of Non Conforming Products in IATF. As each business is different, additional documents or revisions would be required to meet your organization’s specific needs, requirements, context, risk profile, etc. If after reading through all of these documents, you feel like you still need a consulting partner to help you develop your new documents – Contact Us. We’re always looking for interesting new clients and projects.
1.0 Process Approach of Process of Control of Non Conforming Products
2.0 Turtle diagram of Control of Non Conforming Products
3.0 Corrective & Preventive Action ( 8-Discipline Report)
| Part Name | Model | ||||||||||||||||||
| Part No. | Supplier part No. | ||||||||||||||||||
| Drg. Ref. | Drg. Modification status | ||||||||||||||||||
| Date | Feedback form | ||||||||||||||||||
| (1) PROBLEM AWARENESS | |||||||||||||||||||
| Problem Scope | Problem Severity | Problem Source % Defect | |||||||||||||||||
| New | Safety | ||||||||||||||||||
| Regulatory | |||||||||||||||||||
| Functioonal | |||||||||||||||||||
| Existing | Aesthetic | ||||||||||||||||||
| Reliability | |||||||||||||||||||
| Reopened | |||||||||||||||||||
| Others | |||||||||||||||||||
| (2) PROBLEM DEFINITION | |||||||||||||||||||
| (3) CONTAINMENT ACTION / SHORT TERM ACTION | |||||||||||||||||||
| NO. | Immediate Action Taken | Completion | Responsible | Date | |||||||||||||||
| (4) ROOT CAUSES (ttached root cause analysis Sheet -Fish Bone, Brainstorming,Pareto analysis,Why-Why analysis etc.) | |||||||||||||||||||
| (5) CORRECTIVE ACTIONS | VERIFICATION | DATE | METHOD | RESULTS | |||||||||||||||
| TARGET | EFFECTIVE | ||||||||||||||||||
| (6) PREVENTION | (6) VERIFICATION | DATE | METHOD | RESULTS | |||||||||||||||
| RESPONSIBILITY | TARGET | EFFECTIVE | |||||||||||||||||
| (7) REVIEW -DOCUMENTS / SYSTEM(Attach copies of all revised documents) | |||||||||||||||||||
| No. | QMS DOCUMENT | IF YES | RESPONSIBLE | PLANNED DATE | ACTUAL DATE | STATUS | |||||||||||||
| 1 | Control Plan | ||||||||||||||||||
| 2 | Process sheet | ||||||||||||||||||
| 3 | Drawing / Process flow diagram | ||||||||||||||||||
| 4 | PFMEA / DFMEA / PPAP | ||||||||||||||||||
| 5 | Process Map | ||||||||||||||||||
| 6 | Acceptance Standard | ||||||||||||||||||
| 7 | PM checklist | ||||||||||||||||||
| 8 | Work Instruction / Calibration Plan | ||||||||||||||||||
| (8) PROBLEM CLOSURE & SIGN-OFF | |||||||||||||||||||
| PROBLEM PROGRESS SUMMARY | CLOSURE SIGN-OFF | ||||||||||||||||||
| S.No. | Phase | Start date | End date | Team Member | Area | Sign-off | |||||||||||||
| 1 | Problem Definition | ||||||||||||||||||
| 2 | Containment action | ||||||||||||||||||
| 3 | Root cause analysis | ||||||||||||||||||
| 4 | Corrective action | ||||||||||||||||||
| 5 | Solution confirmation | ||||||||||||||||||
| 6 | Closure | ||||||||||||||||||
| MANAGEMENT VERIFICATION & CLOSURE | |||||||||||||||||||
| Sign | |||||||||||||||||||
| Date | |||||||||||||||||||
| Name | |||||||||||||||||||
| Head | Manufacturing Chief | Quality Chief | Design chief | management Represntative | Plant Head | ||||||||||||||
4.0 Deviation Request
| DEPT. PROCESS/AREA : DATE: TIME: MACHINE : PART DESCRIPTION : PART NO: CUSTOMER: IR NO: DEV. QTY: LOT NO : MRN NO: MATERIAL: GRADE/FINISH : | |||||||||
| NATURE OF DEVIATION | REASON | ||||||||
| S.NO. | PARAMETER | SPECIFICATION | ACTUAL | ||||||
| | |||||||||
| REQUESTED BY: | |||||||||
| DETAILS OF ATLEAST 3 PREVIOUS LOTS | |||||||||
| S.No | Supplied Qty | Actepted Qty. | Rej Qty. | Deviation if Any | |||||
| | |||||||||
| CORRECTIVE ACTION SUGGESTED | |||||||||
| ACTION PLAN | RESP. | TG. DATE | SIGN | ||||||
| CORRECTION & DISPOSITION: ACCEPTED UNDER DEVIATION WITH /WITHOUT REPAIR: TO BE REWORKED /CHANGED: REGRADED FOR ALTERNATIVE APPLICATION: REJECTED OR SCRAPPED: TO BE SORTED NOW/ LATER STAGE: | |||||||||
| FINAL REMARKS | |||||||||
| DISPOSITION AUTHORITY | |||||||||
5.0 Disposal Note cum Rework Data
| DISPOSITION AUTHORITY: | |||||||||||||||
| Deptt.:- | Period :- | ||||||||||||||
| S.No. | Part Name | Prod | Rej Pcs. | PPM (Rej.) | Nature of Rej. | Root cause | Action Plan | Cost/piece | Total Rej.cost | Rework Pcs. | PPM (Rew.) | Nature of Rework. | Root cause | Action Plan | Remarks |
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| Prepared By | Verify By | Approved by (DGM) | Approved by ( Director ) | ||||||||||||