The NCR is written once and read many times: by the board, by the customer's engineer, by the corrective action team, by an auditor a year later. Write it for them. The single most useful habit is to write the requirement, with its revision, beside what was found.
| Field | A thin NCR | A useful NCR |
|---|---|---|
| Requirement | Length | Length 0.500 in +/- 0.002 in, drawing 9020-050 rev C |
| What was found | Too long | 0.503 to 0.504 in on all 15 parts, measured with micrometer MC-07 |
| Quantity | Some | 15 of 15 in lot L-2595; lot L-2596 checked, conforming |
| Where found | Inspection | Final inspection, before the certificate of conformance was signed |
| Cause, as known | Operator | Saw stop block set to the old length after the program change; investigation to confirm |
| Containment | Done | Cage, 15 pieces, tag NCR-26-188; no other lots cut since the change |
Record every nonconformance on the log (D19), including the ones that will be reworked in ten minutes. Small, fast NCRs are where the trend shows first: five ten-minute reworks of the same burr are a process telling you something. Fill in the cost, even roughly: material and labor lost or redone, sorting, freight. It does not need to be exact to show what late detection costs.
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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.