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The CAPA Command Kit HandbookChapter 1 of 15

Why corrective action systems stall

Corrective action is the part of a quality system that should get better every month. In practice it is often the part that quietly gets worse. The patterns are the same in almost every shop we have worked in:

  • Closed on implementation, not on proof. The record closes the day the action goes in. Nobody comes back to see whether it worked.
  • Causes that stop at a person. 'Operator error' and 'retrained' appear on a third of the records. The condition that made the error likely is still there.
  • Repeats nobody connects. The same failure mode returns on a different part number, a different shift or from a different supplier, under a new NCR number.
  • Everything is a CAPA. Every minor slip opens a full corrective action, the log fills up, and the important ones drown.
  • No consequence for overdue. Due dates move. There is no point at which an overdue action goes to someone who can unblock it.
  • Metrics that reward closing. On-time closure looks good on a chart and teaches everyone to close early.

None of these is a paperwork problem, and none is solved by a better form. They are solved by a workflow with clear gates, an owner for the system as well as for each action, and a short, regular review that looks at the right numbers. That is what this kit gives you.

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A management aid, not certification or a registrar audit. Using it does not by itself show conformity to AS9100D or any other standard, and your customers' requirements may add to it.

Clause numbers refer to AS9100D (SAE AS9100 Rev D) unless another document is named. The standards' text is not reproduced here: use your own licensed copy.

Aegis Insights are our own guidance, labeled wherever they appear: how we approach this work, not a requirement of any standard or customer.