8. The audit architecture: corrective & preventative action
Audits are not administrative exercises designed to catch operators making mistakes. They are a critical engineering diagnostic tool for assessing process control. Physical principles apply to manufacturing: a process left unchecked will drift over time due to equipment wear and human variables.
This chapter defines the structure of how we handle non-conformances, internal Material Review Boards,
- 8.1 NCR workflow: detect, quarantine, disposition, close
A Non-Conformance Report (NCR) acts as the immune system of the factory. It flags manufacturing risks—defective parts, process drifts, or documentation errors—and isolates them before they can reach t...
- 8.2 Internal MRB & quarantine discipline
The Material Review Board (MRB) process is a formal engineering investigation, not simply a repair area or a storage space for production mistakes. Every item placed in the MRB cage represents a failu...
- 8.3 Root cause analysis & CAPA
A useful principle in manufacturing is that addressing the same production issue repeatedly indicates that the CAPA (Corrective and Preventive Action) system needs improvement. Root Cause Analysis (RC...
- 8.4 Containment playbook: suspect lots, line stop triggers & escape handling
When a critical defect is first detected on the floor, the primary engineering priority is **Containment**. Before initiating a Root Cause Analysis, it is essential to isolate the risk, define the sus...
- 8.5 RMA processing & field failure analysis
Return Merchandise Authorization (RMA) field returns are a crucial source of manufacturing truth. While internal factory yield metrics measure the ability to assemble a product under controlled condit...