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8.1 NCR Workflow: Detect, Quarantine, Disposition, Close

A Non-Conformance Report (NCR) is not a bureaucratic punishment; it is the immune system of the factory. It flags foreign risks—defective parts, process drifts, or documentation errors—and isolates them before they infect the final product. A sloppy NCR process results in "escapes," where known bad units are accidentally shipped because the paperwork was closed but the physical quarantine was breached. This chapter defines the rigid lifecycle of a non-conformance.

Phase 1: Detect & Document

Identification must be immediate and objective. Subjectivity at the detection stage hides the true scale of quality issues.

Trigger: Any material, component, or sub-assembly that does not meet the drawing, BOM, or IPC standard.

Action:

  • If a defect is found -> Then Tag the physical unit immediately. Do not "set it aside for later."
  • If the defect rate exceeds the Shift Trigger (e.g., 3 consecutive failures) -> Then Stop the Line and notify the Quality Engineer.

Mandatory Data Fields:

  1. Part Number & Serial/Lot Number: Traceability is non-negotiable.
  2. Defect Code: Standardized taxonomy (e.g., "Solder Short" not "Bad Board").
  3. Evidence: Photo or measurement data attached to the digital record.

Pro-Tip: "Pending Inspection" is a dangerous state. If a unit is not explicitly "Passed," it is effectively "Failed" until proven otherwise. Treat unverified material as non-conforming.

Phase 2: Quarantine (Containment)

The gap between detection and physical isolation is where escapes happen.

Physical Control:

  • If NCR is generated -> Then Move unit to the locked Red Box or designated Cage.
  • If units are too large to move (e.g., Pallets) -> Then Apply Red "STOP / REJECT" tape and block the system transaction (ERP Lock).

Digital Control:

Block the serial number in the MES (Manufacturing Execution System). This prevents the unit from being scanned at the next station.

Phase 3: Disposition & Authority Matrix

Disposition is a technical decision, not a negotiation. The authority to decide the fate of a product scales with risk and cost. Do not bypass this hierarchy.

The Authority Matrix

Role

Authority Scope

Allowed Dispositions

Financial Limit

Inspector / Operator

Detection Only

N/A (Must Escalate)

$0

Quality Engineer (QE)

Standard Process Issues

Rework (Standard only), Scrap (Low Value), RTV

< $500

Quality Manager

High Value / Non-Standard

Scrap (High Value), Repair (Non-Standard)

< $5,000

MRB (Eng + Quality + Ops)

Design / Risk / Customer

UAI (Use As Is), Deviation Waiver

> $5,000

Decision Logic:

  • If the fix is defined in a Standard Operating Procedure (SOP) -> Then QE can approve Standard Rework.
  • If the unit does not meet spec but is functionally safe and requires customer approval -> Then MRB must approve UAI (Use As Is).
  • If recovery cost > 50% of unit value -> Then Scrap.

Phase 4: Close & Verify

An NCR is not closed when the signature is added; it is closed when the risk is eliminated.

Requirements for Closure:

  1. Execution Verification: The rework was performed, AND the unit passed re-inspection/re-test.
  2. Inventory Adjustment: Scrap quantities are removed from ERP.
  3. Root Cause Link: If the NCR was systemic, it must be linked to a CAPA (Corrective Action) number.

Pro-Tip: Never allow "Open" NCRs to age beyond 30 days. Old NCRs represent stagnant inventory and unresolved risks. Force a disposition: fix it or scrap it.

Final Checklist

Parameter

Rule / Threshold

Tagging Rule

Physical Red Tag must match Digital Record ID.

Quarantine Discipline

Only authorized Quality personnel hold keys to the Quarantine Cage.

UAI Authority

NEVER Inspector or Line Lead. Requires Engineering/MRB sign-off.

Scrap Authorization

Must include "Scrap Reason Code" for Cost of Quality (CoQ) tracking.

Re-Test Requirement

Any Reworked unit must restart testing from the previous passing station.

Closure Speed

Disposition within 48 hours; Physical closure within 5 days.

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