Quality Management for Job Shops

NCRs: When things go wrong

A Nonconformance Report (NCR) documents when a part, process, or material doesn't meet specifications. The NCR workflow: identify the problem, document what happened, disposition the nonconforming material (use-as-is, rework, scrap, return to vendor), and determine if a corrective action is needed.

The key is consistency. Every NCR should be documented the same way, reviewed by the same process, and tracked to closure. When an auditor asks "show me your NCRs from Q4," you should be able to pull them up in seconds — not dig through email.

CAPAs: Preventing recurrence

Corrective and Preventive Actions (CAPAs) go beyond fixing the immediate problem. They investigate root cause and implement changes to prevent recurrence. A proper CAPA has 5 steps: (1) describe the problem, (2) investigate root cause, (3) implement corrective action, (4) verify effectiveness, and (5) close with evidence.

The verification step is where most shops fail. They implement a fix but never check if it actually worked. Six months later, the same problem recurs and the auditor asks why your CAPA didn't stick.

Inspections and calibration

Inspection planning defines what gets measured, how, and at what frequency. First-article inspection verifies a new setup produces conforming parts. In-process inspection catches issues before they propagate. Final inspection confirms the lot meets customer requirements.

Calibration tracking ensures your measurement tools are accurate. Every gauge, micrometer, and CMM probe needs a calibration schedule, and out-of-calibration instruments need to trigger a review of everything measured with them since the last good calibration.