NON CONFORMANCE REPORTING

INTEGRATED MANAGEMENT SYSTEM

PCD-QSC-SOP-05,06

WHAT IS AN NCR ?

• A report issued when a product, process orprocedure does not comply with the set standards for a product, process or procedure under inspection.

• An NCR is any significant deficiency.• A means of tracking actions. • A tool to put right things that are going

wrong.• A means of stopping repeated errors.

WHAT IS AN NCR ?• NCR’s are used to record findings from

internal and external audits that require addressing.

• Work that was not built as indicated in approved drawings

• Work that fails to meet specified tolerances as established in project specifications.

WHAT IS AN NCR ?

• Work that is being performed using non-approved methods or standards

• When the testing and inspection plan is not followed as agreed

• When testing results demonstrate that the product does not meet established and approved standards

• When a material is used and has not been approved as a substitute (equal or similar)

When design is not accurate and does not represents actual field conditions

When the approved procedure wasnot followed and quality defectshave been identify by the project team.

THE IMPORTANCE OF NON CONFORMANCE

REPORTING

For want of a nail a shoe was lost, for want of a shoe a horse was lost, for want of a horse a rider was lost, for want of a rider an army was lost, for want of an army a battle was lost, for want of a battle the war was lost, for want of the war the kingdom was lost, And all for the want of a little horseshoe nail.

5 Why Questions?

Why was the Kingdom lost?Because the war was lost.Why was the war lost?Because the battle was lost.Why was the battle lost?Because the army was lost.Why was the army lost?Because the rider was lost.

Why was the rider lost?Because the horse was lost.

Why was the horse lost?Because the shoe was lost.

Why was the shoe lost?Because the nail was lost

Why was the nail of the shoe lost?

.............................?

PCD-QSC-SOP-05DIFFERENT TYPES OF NON CONFORMITY

IDENTIFIED IN CPD ACTIVITIES

• NON CONFORIMITY RELATED TO PROJECT PROCURED MATERIAL.

• NON CONFORMITY RELATED TO SERVICE CONTRACT DEVIATIONS.

• NON CONFORMITY RELATED TO END USER (CUSTOMER)COMPLAINTS.

BS EN ISO 9001:20088.5.2 Corrective action

The organization shall take action to eliminate the causes of nonconformities in order to prevent recurrence.Corrective actions shall be appropriate to the effects of the nonconformities encountered.A documented procedure shall be established to define requirements fora) reviewing nonconformities (including customer complaints),b) determining the causes of nonconformities,c) evaluating the need for action to ensure that nonconformities do not recur,d) determining and implementing action needed,e) records of the results of action taken , andf) reviewing the effectiveness of the corrective action taken.

BS EN ISO 9001:20088.5.3 Preventive action

The organization shall determine action to eliminate the causes of potential nonconformities in order to prevent their occurrence. Preventive actions shall be appropriate to the effects of the potential problems.A documented procedure shall be established to define requirements fora) determining potential nonconformities and their causes,b) evaluating the need for action to prevent occurrence of nonconformities,c) determining and implementing action needed,d) records of results of action taken , ande) reviewing the effectiveness of the preventive action taken.

Root Cause Analysis

Difficulties in tracking down the root causesWhere do you draw the line?At the Joint Venture?At the Parent Company?At the Client?At the Regulator?At the Big Bang – creation of the universe?What are the stop rules?There are no natural break-points, only artificially imposed ones.The goal is to establish what happened and how to stop it happening again.The logical stop point would seem to be where managers might reasonably be expected to exercise controlA sad story will help to illustrate this point

What was supposed to happen?• ________________________• ________________________• ________________________• ________________________• ________________________• ________________________

Why was there a difference?• ________________________• ________________________• ________________________• ________________________• ________________________• ________________________

What actually happened?(and did we get hurt?)

• ________________________• ________________________• ________________________•________________________ • ________________________• ________________________

What have we learnt?Plus actions

• ________________________• ________________________• ________________________• ________________________• ________________________• ________________________

Root Cause Analysis

I will not close out the NCR if the evidence is not provided or theaction to prevent recurrence is not adequate.

Closure Approval:

Closure:The Closure must be completedin full With all the evidence.

THANK YOU