Worked example: one problem through the whole kit | CAPA Command Kit

Worked example

Meridian Aerostructures: the oversize bore

Intake (B02): customer reject report CR-118, 4 of 40 housings with an oversize bore. Triage: customer escape, so a corrective action, priority high, owner J. Alvarez, containment within 24 hours.

Contain (B11, B12): all work in process and stock sorted 100 percent the next day; the customer held the rest of the lot for a sort by our inspector. Six oversize parts found in all; NCR-26-207 records the scrap (D19).

Investigate (B04, B06; 8D on B03 because it was an escape): the finish-boring insert ran 260 parts with no tool-life limit. Escape cause: the bore check was 1 in 10, with a gauge missing from the calibration recall list. Confirmed: the bore grew steadily with part count; a new insert brought it back.

Act (B08): tool-life counter in the program, check frequency raised, gauge added to recall, work instruction revised; extended to two similar parts on two machines. Criterion set before implementation: zero oversize bores in 10 lots and 90 days, and capability of 1.33 or higher.

Prove (B08): 11 lots, no findings, capability 1.58. All five closure checks Yes; closed by R. Chen.

Review (B09, B10): shown effective on the program dashboard; the repeat register linked an older bore NCR on a sister part, now covered by the extended action; reported at the next management review.

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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.

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