Controlling Nonconforming Product
or FOI's Procedure
Controlling Nonconforming Product (or FOI's)
is basically a final stage filter to stop bad output before its too
late (or at least from happening again).
- As stated in the “Providing Services” procedure,
Technicians & Engineers label & segregate nonconformances.
The label includes date, customer, PO, part description, and a brief
description of the nonconformance.
- As stated in the
“Monitoring, Auditing, & Measuring Quality” procedure, Site Managers
maintain a KPI
Log, Trend Charts, & CAP Summary & store it in ABC’s
Nonconforming product and FOI are two of the most critical KPI’s.
- As stated in the “Monitoring, Auditing, & Measuring
Quality” procedure, the CAP Summary should often be supported by a
separate CAP document that tracks all tasks for determining &
correcting the root cause. The plan should consider short-term tasks to
correct the immediate problem & long-term tasks to prevent
recurrence. See the documents called Problem
Solving & Escalating
Problems for tips & techniques. Determine the following
disposition to the nonconforming product or FOI:
consider further remedial response by ABC or its Supplier:
(repair) or Regrade
- Deviation Permit
stated in the “Continually Improving” procedure, Site Managers chair
Customer Performance Review Meetings each month with each customer to do
the following. Nonconforming product & FOI are discussed in this
meeting as part of these agenda items:
- Reprocess other material
- Pay to replace
KPI Status Report.
- Discuss the plan, status, due
date, & result of Quality Issues (especially nonconforming products
& FOI’s) concerning that customer.
- ABC = Fake
name of company used in our procedures.
- CAP = Corrective Action Plan
- DCS = Document
Control System for users to write, approve, publish, find, & read
- FOI = Failed On Install
= Key Performance Indicator
- Nonconformance = A product is
nonconforming when it fails to meet specified acceptance criteria or
when discrepancies are noted which should be reported to the customer. A
part may become nonconforming because of ABC processing, Copper
contamination of a Non-Copper part, wear from the customer's use, damage
in shipping, loss, etc.