3.7 Recall Drill Procedure + “Reverse Genealogy Report” Template

A recall is not a "possibility"; it is a statistical certainty. When a raw material defect is discovered, the difference between a minor logistical annoyance (recalling 500 units) and a company-ending event (recalling 50,000 units) is the precision of your data scope. Traceability is the insurance policy; the Recall Drill is the fire inspection to prove the policy pays out.

The Mandate: Drill Cadence

Do not wait for a crisis to test your query speed. Execute a "Mock Recall" on a strict schedule.

• Frequency: Bi-Annual (Every 6 months).
• Method: Double-Blind. The Quality Manager selects a target (e.g., "Capacitor Lot X") without warning Operations.
• Objective: Produce the Containment List within the defined SLA (Service Level Agreement).

Drill Scenarios

Test the system against the three vectors of failure.

Scenario A: The Poisoned Ingredient (Upstream)

• Trigger: Supplier notifies you that Lot_A123 of Resistor_R1 is defective.
• Query Logic: Select Parent_SN where Child_Lot = 'Lot_A123'.
• Goal: Find every finished good containing this specific batch.

Scenario B: The Process Excursion (Internal)

• Trigger: Maintenance discovers Reflow Oven 3 had a broken fan between 08:00 and 10:00 yesterday.
• Query Logic: Select Parent_SN where Machine_ID = 'Oven_3' AND Timestamp BETWEEN '08:00' AND '10:00'.
• Goal: Quarantine only the units processed during the thermal excursion.

Scenario C: The Contagion (Downstream/Field)

• Trigger: Customer returns 3 units with cracked screens.
• Query Logic: Commonality Analysis. Compare the genealogy trees of the 3 failed units.
• Goal: Identify the common factor (e.g., "All 3 used Glass Lot Z").

Success Criteria (The SLA)

A drill is a "Fail" if it produces the correct data too slowly.

• Time-to-List (TTL): Target < 1 Hour. (If it takes 24 hours to query the database, the ship has already left the port).
• Completeness: 100%. Missing a single unit implies a "False Negative" risk, forcing you to recall the entire month's production to be safe.
• Containment: Physical quarantine of WIP units within 4 Hours.

Pro-Tip: Do not rely on ERP for tree traversal. ERP structures are flat. Use the MES or a dedicated Graph Database (e.g., Neo4j) for deep genealogy queries.

The "Reverse Genealogy" Report Template

When the CEO asks "How bad is it?", do not send a raw SQL dump. Use this standardized template to categorize risk.

Section 1: Scope Definition

• Trigger: [Input Value, e.g., "Solder Paste Lot 99"]
• Date Range: [Start Date] to [End Date]
• Total Affected Count: [Integer]

Section 2: Disposition Matrix (The "Where is it?" Table)

Categorize the affected units by their current physical state to determine financial impact.

Category	Definition	Count	Action Required
WIP (Factory)	Units currently on the production line.	[Qty]	Immediate Stop. Route to Rework/Scrap.
Inventory (FGI)	Units in the warehouse (Boxed).	[Qty]	Administrative Hold. Do not ship. Unbox for rework.
In-Transit	Shipped but not arrived at Customer.	[Qty]	Recall from Carrier. Intercept shipment.
Delivered	In Customer possession.	[Qty]	Field Recall. Issue RMA. (Highest Liability).
Scrapped	Units already destroyed.	[Qty]	None. (Accounting Write-off only).

Section 3: The Hit List (Data Extract)

(Attach as CSV)

• Parent_Serial_Number
• Current_Location (e.g., "Pallet 5, Rack B" or "Customer X")
• Work_Order_ID
• Date_Produced

Post-Drill Analysis (The "Autopsy")

If the drill fails, fix the system.

• If Time-to-List > 4 Hours → Then Index the Database. Your query performance is inadequate.
• If "Ghost Units" found (System says FGI, Warehouse says Empty) → Then Trigger full Inventory Audit.
• If Data Gap (e.g., "Unknown Component Lot") → Then Halt Line. Enforce Supplier Interlocks (See Page 3.3).

Final Checklist

Category	Metric / Control	Threshold / Rule
Cadence	Drill Frequency	Minimum 2x / Year (Bi-Annual).
Speed	Time-to-List	< 1 Hour to generate the list of affected SNs.
Accuracy	Capture Rate	100%. Zero tolerance for missing links.
Scope	Dimensions	Drill must test Supplier (Lot), Internal (Time), and Field (SN) triggers.
Reporting	Disposition	Report must split counts by WIP / FGI / Shipped.
Containment	Physical Action	Affected WIP must be electronically locked (Hold status) immediately.