Course overview
By the end of this e-Learning course management team members will be able to resolve NCRs (Nonconformity Reports) and CARs (Corrective Action Requests) in a timely and effective manner and understand how to monitor and ‘actively manage’ both QMS performance and process-level effectiveness (PEARs).
Sources of NCRs and CARs come from CB & internal audits, customer audits & complaints, manufacturing issues & process effectiveness and product nonconformities resolved by MRB investigations
The course specifically addresses ISO-9001-based standards (clause 10.2 Nonconformity and corrective action) and is applicable to AS9100 series, AS13100, IATF 16949, AQAP 2110 and AQAP 2310. For aerospace, the root cause codes now being requested by the IAQG are incorporated.
An integral part of this course is instruction in a battery of problem solving methods including ‘Fishbone’ and ‘5-WHYs’ in tandem!
downloadable (pdf) Delegate Workbook is included with this e-Learning course
Also learn how to appeal against an NCR – and how to justify the request!
Course details
Introduction
Explanation of the Sections and their learning objectives – Modules – Quizzes & Exercises
Downloading the Delegate Workbook (pdf)
Purpose and value of audits
Understand that audits uncover deficiencies in QMS processes (nonconformities)
Learn that audits evaluate evidence and generate findings, and there are three types of audit
Appreciate that audit findings provide top management with information on the performance and effectiveness of the QMS
Nonconformities and corrective actions explained
Understand nonconformities and applicable QMS requirements
Learn about sources of nonconformities, their criteria and types
Appreciate the difference between correction, corrective action and preventive action
Understand ISO 9001-based standards common requirements for corrective action
Standards, clauses and audit questions
Appreciate how auditors create their questions
Understand the structure of QMS standards
See how auditors creates audit questions
Audit activities, sequence and NCRs
Understand the sequence of audit events
Nonconformity report (NCR) template
Organization’s planned activities template
The 1-page nonconformity report (NCR) form
Classification of NCRs
Understand how CB auditors classify NCRs as either major and minor
Appreciate the difference between ISO 9001 and AS9100 classifications
Learn how to respond to a request for containment, soft grading and repeat nonconformities
1. Nonconformities based on audit findings
Appreciate how auditors record the details of a nonconformity on an NCR
Learn now to react to an NCR, determine the root cause(s) and take necessary corrective action
Understand how to summarise and record the organization’s planned activities
2. Nonconformities based on customer performance and satisfaction
Understand AS9100 requirements for customer satisfaction
Learn how to deploy corrective action(s)
3. Nonconformities based on current manufacturing issues and operation process effectiveness
Understand process effectiveness requires conformity and performance
Become proficient in handling and scoring ‘PEARs’
Learn how to deploy corrective action(s)
4. Nonconformities based on new product development
Understand the principles and practices of new product development – and the ‘quality focused’ approach imposed by APQP & PPAP
Learn how to deploy corrective action(s)
5. Nonconformities based on supplier issues
Understand that your organization is responsible for the conformity of all externally provided processes, products, and services
Learn how to monitor supplier performance
Appreciate the need to ‘flow down’ corrective actions to suppliers
Learn how to deploy corrective action(s)
6. Product nonconformities resolved by MRB investigations
Learn about the role and constitution of a Material Review Board (MRB)
Appreciate the related AS9100 requirements
Understand the MRB process used to deal with nonconforming product
Summary of root cause determination models
Learn about different models and methodologies for determining root causes
Appreciate the IAQG root causes classification
Learn how to deploy corrective action(s) and never accept ‘human error’ as a root cause!
Corrective action responsibilities for QMS audit nonconformities
Learn about audit activities, participants and their responsibilities
Appreciate how the CBs manage nonconformities for the certification program
Understand the documentation of the nonconformity report (NCR) – and who is responsible for what
Reviewing/appealing an auditor’s NCR
Understand that auditees are required to acknowledge, respond and react to NCRs
Learn that they can, of course, reject them – provided this can be justified!
Example: audit of inspection gauge calibration
Auditee’s appeal for NCR withdrawal – justified?
Auditee’s appeal upheld – NCR withdrawn
Qualifications & benefits
The benefits of e-Learning are numerous; not only are they extremely cost-effective but they provide students with convenience and flexibility as they embark on their learning journey.
attain in-depth knowledge & skills without the pressure of exams
You can complete your training whenever and wherever you want, and at your own pace.
Companies do not have to tie-up entire teams at the same time as is the case with conventional classroom-based training
Each section of this e-learning course incorporates Quizzes and Exercises to ensure student understanding. Automated tutor hints/advisement are also provided, as necessary.
On successful completion of the course and its quizzes/exercises, delegates can download their Training Certificate.