Nonconformance and Rework Procedure

Purpose. This procedure sets out how nonconforming product and process deviations are identified, quarantined, recorded, dispositioned and corrected across all product streams.

1.Identifying and quarantining

Any worker who finds product that does not match the drawing, the standard, the setting sheet or the approved sample must stop the run or the packing, separate the product, attach a red quarantine tag with the job card number and quantity, and tell the supervisor. The supervisor must raise an entry in the Quality Nonconformance Register on the same shift. Product must not be moved from quarantine until a disposition is recorded.

2.Recording

The register entry must state the product, job card, material lot or compound batch, tool version, machine, shift, the nonconformance found, the quantity affected and the inspection that found it. Photographs and measurement results must be attached. Where a customer has reported the problem, the customer complaint reference is recorded.

3.Disposition

The Technical, Quality and WHS Manager, or the supervisor within their delegated limits, decides the disposition: rework to conform, regrind where the setting sheet allows, accept with concession from the customer, or scrap. Rework must be done to a written rework instruction and the reworked product must be re-inspected. Concessions must be in writing from the customer before the product ships. Scrap must be weighed and recorded.

• Rework: written instruction, re-inspection, record on job card
• Regrind: only at the percentage and from the source on the setting sheet
• Accept with concession: customer approval in writing before dispatch
• Scrap: weighed, recorded, segregated by material

4.Root cause and corrective action

For a repeat nonconformance, a customer complaint, a cable test failure or any nonconformance affecting more than 200 parts or 500 metres, the supervisor and the technical team must investigate root cause using the setting sheet, process records, material certificates and tool history. A corrective action must be assigned an owner and a due date and verified before the register entry is closed.

5.Process deviations

Any change to a process outside the limits on the setting sheet, any run started without first-off approval and any use of regrind outside the sheet must be recorded as a process deviation in the register even if the product conforms.

6.Review

Open register entries and overdue corrective actions are reviewed at the weekly production meeting and the monthly operations, quality and safety review.