SC QUALITY GUILDNonconforming material and MRB disposition
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Record a nonconformance, reconcile where every suspect part is, split the nonconforming quantity across dispositions, and check approvals, concessions and the link to corrective action.
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The control of nonconforming output
ISO 9001:2015 clause 8.7 requires nonconforming outputs to be identified and kept under control so they are not used or delivered by mistake. The sequence a technician follows is the same everywhere:
- Identify the product with a tag or label stating the nonconformance.
- Segregate it in a controlled area (a hold cage or red-tag area) where practical.
- Contain by finding every suspect piece: stores, work in process, finished goods, in transit and at the customer. The quantities located should add up to the lot.
- Evaluate and disposition through a material review board (MRB) or another authorized person.
- Record the nonconformity, the actions taken, any concessions and who authorized the decision.
The dispositions
- Use as is: the part is accepted without change. It still does not meet the requirement, so it needs engineering justification and often a customer concession (also called a waiver).
- Repair: action that makes the part acceptable for its intended use but not conforming to the original requirement. It needs the same approval as use as is.
- Rework: action that makes the part conform to the original requirement. Reworked parts are reinspected before release.
- Regrade: reassign the part to a different grade or use where it does conform.
- Return to supplier and scrap: scrap is made unusable so it cannot drift back into production.
Disposition is not corrective action
The disposition deals with the parts in hand. A corrective action removes the cause so the problem does not recur. A good record links the two and shows the cost of disposition, which is part of the cost of poor quality.
Common traps
- Confusing rework with repair, the most common exam distinction in this area.
- A deviation is permission granted before the work to depart from a requirement; a concession is granted after the nonconforming product exists.
- Closing containment while part of the lot is unaccounted for.
- Dispositioning critical characteristics by use as is.