4.5 Supplier Corrective Action (SCAR/8D) + Effectiveness Check

A Supplier Corrective Action Request (SCAR) is not a "Complaintcomplaint Form."form" or an invitation to apologize. It is a formalformal, legal demand for ana systemic engineering investigationchange. intoIf you merely ask a processsupplier failure.to "fix the part," they will rework the inventory and ship you the same defect next month. The goal isof nota to fix the part (that is Rework); the goalSCAR is to fixforce a mutation in the systemsupplier's process so that produced the part.defect Thisbecomes chapterphysically defines the mandatory 8D methodology, the response timelines, and the validation protocols requiredimpossible to close a SCAR.produce.

SCAR Triggers and(When Escalationto Pull the Alarm)

We doDo not issuedilute SCARsthe power of a SCAR by issuing one for every minor scratch. We issueUse them when the process iscapability outhas ofcollapsed.

control.

The Escalation Logic:

• Level 1: Critical (Stop Ship)
  • TriggerTrigger:: Safety hazard, Regulatory violation,violation (RoHS/REACH), or any defect causing a "Line Down" event > 4 hours.
  • MandateResponse:: 24-hour initialContainment response(D3) required.is mandatory.
• Level 2: Major (Systemic)
  • TriggerTrigger:: Repeat defect (same MPN, same failure mode within 390 months)days) or Defect Rate > 1% Defect Rate..
  • MandateResponse:: Full Standard8D 8DReport required.
• Level 3: Minor (Trend)
  • TriggerTrigger:: NegativeDocumentation errors or negative trend in Supplier Scorecard or documentation errors.Scorecard.
  • MandateResponse:: Informal "Corrective Action Plan"Plan (CAP) accepted.

The 8D Methodology (Mandatory Format)Architecture)

We reject "email explanations." Suppliers must submit their response using the standard Eight Disciplines (8D) format. "Email explanations" are rejected.structure.

• D3: Interim Containment Action(The (ICA)Tourniquet)
  • GoalRequirement:: StopIsolate the bleeding.
  • Requirement:victim. The supplier must define exactly how they have segregatedscreened suspect stock (e.g., "100% visual check under 4x magnification") and whathow screeningthey methodmarked isthe inclean placeboxes for(e.g., new"Green shipments.Dot on label").
  • TimelineDeadline:: Must be submitted within 24 hours.Hours.
• D4: Root Cause Analysis (RCA)The Pathology)
  • Goal: Identify the "Escape Point" and the "Creation Point."
  • ProhibitionRule:: "Operator Error" is notNOT a Root Cause. If an operator made a mistake, the root cause isfailed, the process thatfailed allowedto prevent the mistake (e.g., lack of fixtures, confusing instructions).error.
  • ToolsTools:: Must useshow evidence of 5 Whys or Fishbone Diagram(Ishikawa). analysis.
  • Bad D4: "Worker didn't follow SOP."
  • Good D4: "Fixture allowed part to be loaded backwards because there was no keying pin."
• D5/D6: Permanent Corrective Action (PCA)The Fix)
  • GoalGoal:: SystemicHardware change, not software/wetware change.
  • Requirement: ImplementationHierarchy of Hardware ChangesIntervention: (e.g., modified tooling, new sensors) or
    1. Poka-Yoke (Mistake Proofing): Physical modification (Strongest).
    2. Process TrainingChange: Automated inspection/sensors.
    3. Training: Informational update (Weakest - Reject if this is consideredthe aonly weak countermeasure.action).
• D7: Prevention (System Update)
  • RequirementRequirement:: The fix must propagate to the documentation. Update the FMEAPFMEA (Failureto Modelower EffectsOccurrence/Detection Analysis)scores) and the Control Plan to reflect the new risk controls.Plan.

Response Timelines

A SCAR is a ticking clock. Delays trigger automatic escalation.

Phase	Milestone	Deadline (from Issuance)	Consequence of Delay
Acknowledgement	D1	24 Hours	Buyer Notification
Containment	D3	24 Hours	New Business Hold
Root Cause	D4	5 Business Days	Supplier Scorecard Deduction
Final Report	D8	14 Business Days	Management Escalation

Effectiveness Verification (VoE)

A SCAR is never closed based on a promise.promise; Itit is closed based on evidence.

The "3-Shipment" Rule:

• The Validation WindowIF: ThePCA is implemented -> THEN SCAR remains inenters "Monitoring" statusstate.
• Action: forThe next 3 consecutive shipments aftermust be defect-free.
  • Pro-Tip: Tag these shipments in the PCAERP implementation.
  • Verificationsystem Methods:
    1. Incomingas Data:"Probationary." IQC performsmust perform 100% checkinspection on the specific defectcharacteristic forthat thefailed.

next 3 lots.

Audit: SQE verifies the physical fix (e.g., the new sensor) during the next site visit.

Capability Data: Supplier submits new Cpk data showing process shift.

Closure: Only the Dannie SQE has the authority to close the SCAR.

Re-Open TriggerLogic:

• IF: If the defect recurs within 6 months,months the-> THEN The SCAR iswas re-openedineffective.
• Action: Re-open as a Level 1 Escalation. (ManagementThe Interventionsupplier's required).Quality Director must present the new plan to our Senior Management.

Final Checklist

SCARControl ElementPoint	StandardCritical Requirement	RiskNon-Negotiable of FailureRule
Containment	<Response 24 HoursTime	FactoryD3 contamination(Containment) within 24 Hours.	Late D3 = New Business Hold.
Root Cause	NoFocus "Operatoron Error"Process/Method.	RecurringReject defects"Retrain Operator" as a Root Cause.
CorrectiveAction Action	Hardware/Process ChangePlan	WeakPhysical/Systemic "training"change.	Must fixesaddress both detection and prevention.
Verification	3 Cleanconsecutive Lotsclean lots.	FalseDo sensenot ofclose securitySCAR without IQC data.
Document UpdateDocumentation	FMEAPFMEA & Control Plan updated.	KnowledgeFix lossmust be institutionalized, not tribal.

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