Architectural Flashing Supply
Start a Quote
Manufacturing QA and continuous improvement · Lesson 4 of 4

Manufacturing QA and continuous improvement: defects, verification and case study

The nonconformance loop from discovery to standard work, who decides a disposition, a worked case of a painted coping formed with the paint on the wrong face, checking that the fix worked with reject rates, a receiving case of white deposit on galvanized flashing, and the evidence packet.

You will be able to: Handle a nonconformance from discovery to a closed loop (stop, segregate, contain, disposition, find the root cause, correct, verify, standardize) and assemble the evidence a reviewer needs.

11 min · 12 slides · 6 questions

All lessons in this module
Slide 1 of 12

From a found defect to a closed loop

A teaching sequence for this course: detect the defect, stop, tag and segregate the parts, contain (check the rest of the batch and what already shipped), decide the disposition, find the root cause, correct it, verify the correction worked, and make it standard work.

Toyota says stopping at an abnormality keeps defective products from flowing on down the line.

From a found defect to a closed loopNine boxes in three rows, read left to right, then right to left, then left to right: detect, stop, tag and segregate; contain, disposition, root cause; correct, verify, standardize. An arrow from standardize loops back to detect. A panel lists the outcomes FAR 46.407 gives for nonconforming supplies: reject; correct or replace; accept or conditionally accept, with the contract naming who decides. An amber-edged band reminds that a quarantine rack is storage: stable stacks that create no hazard.DetectStopTag andsegregateContainDispositionRoot causeCorrectVerifyStandardizethen back to DetectDisposition under FAR 46.407:reject; correct or replace;accept or conditionally accept.The contract names who decides.Quarantine rack is storage:stable stacks, no hazard (1910.176(b)).

Nine steps in a serpentine: detect, stop, tag and segregate, contain, disposition, root cause, correct, verify, standardize, then back to detect. A panel lists the outcomes FAR 46.407 gives for nonconforming supplies (reject; correct or replace; accept or conditionally accept) and a band reminds that a quarantine rack is storage that must not create a hazard.

A teaching sequence for this course, built from Toyota's jidoka, the FAR 46.407 outcomes and the CMS root cause steps; it is not an AFS procedure.

Sources

Videos for this lesson

What this video shows: Toyota's own short explainer on jidoka: a machine stops itself, or an operator stops the line, when something is wrong, so defects do not move on. Checked against the video's description.

Video: The Toyota Production System as Taught by Toyota - Episode 01 by Toyota Motor Corporation, on YouTube. AFS checked its description against this lesson.

Glossary

Conditional acceptance
Under FAR 46.101, acceptance of supplies or services that do not conform to contract quality requirements, or are otherwise incomplete, which the contractor must correct or complete by a specified date.
Disposition
This course's word for the decision on nonconforming supplies. FAR 46.407 gives the federal outcomes: reject them; give the contractor an opportunity to correct or replace them; or accept or conditionally accept them. The contract names who decides.
Verification of effectiveness
Checking, after a corrective action, that the problem really stopped, for example by comparing rejects per 100 pieces before and after. It is the last of the CMS root cause analysis steps.