Why does it occur?
Investigate the design, materials, tooling, process conditions and assembly that can create the failure.
Solutions / Supplier Quality Improvement
Supplier Quality Improvement & Problem Resolution
The same defect. Another batch.
Get to the cause of defects that keep coming back.
Discuss a quality problemBreak the cycle
01
Why does the defect occur?
02
Why do existing controls miss it?
03
See what the work involvesWhat evidence will show the fix works?
Your starting point
You have repeated defects, rejected batches or unstable supplier quality. You need to protect current production and make a change that prevents the problem from recurring.
Why does this problem keep returning?
Distinguish between the cause of the defect and the reason existing controls missed it. Replacing a batch may contain the immediate problem without fixing either.
More inspection can contain a defect.
It may not remove its cause.
Why does it escape?
Investigate the controls and measurement that should detect or prevent the nonconformity.
Protect current production while investigating the cause. Then verify the change in later production. Replacing a batch alone won’t prevent a repeat.
From assessment to implementation01 02 03 04
Define and contain the problem
Agree the defect definition, measurement method and affected scope. Establish temporary controls and clear decisions for suspect stock.
Investigate the cause
Review samples, process settings, revisions and previous actions. Test why the defect occurs and why it gets through the existing controls.
Put corrective actions in place
Link the changes to the supported causes. Assign owners and dates, then verify changes to design, tooling, instructions, measurement or process control.
Check later production
Review results against agreed criteria over an appropriate follow-up period. If the problem returns, revisit the cause rather than repeating the same temporary fix.
What to bring
- Failure definition, defect samples and affected lots
- Inspection data and production or supplier history
- Previous actions, recurrence dates and current containment
What the work can deliver
- Problem definition and containment record
- Cause analysis with evidence and open hypotheses
- Corrective-action plan with named responsibilities
- Effectiveness review and closure criteria