The NCR trend analysis (AQL-F09) is where the monthly meeting finds its corrective action. It depends entirely on how the NCRs are classified, so start there.
Classify on the day
Each NCR gets an operation, a defect type, an origin, where it was found, the shift and a cause category, chosen from fixed lists when the NCR is raised, with the person who found it. Not yet known is an allowed cause; a blank is not. A quarter's NCRs classified from memory before a review produce a Pareto of opinions.
Read four views
| View | Question it answers | What to watch for |
|---|---|---|
| Monthly trend | Did something change? | A month above the upper limit or a long run above the center line; the 2nd shift, supplier and customer-found columns moving on their own |
| Pareto by defect | What is going wrong most? | The top two or three lines, by count and by cost; they can differ |
| Pareto by cause | Why? | The same cause on top for three months is a system problem |
| Pareto by operation; by part | Where do we go and look? | A new machine, a new part, a part family that keeps appearing |
Count and cost
Burrs are frequent and cheap to rework; a wrong drawing revision is rare and scraps the lot. The Paretos show NCR counts and cost side by side. Management asks about money and the floor about frequency; read both, and usually work the top of each.
Repeats
A repeat is the same defect on the same part within ninety days. Each one means a corrective action did not hold, or never reached this part. Take repeats back to their original corrective action, not to a new one, and record them on the Repeat Finding Analysis Register (AQL-B10). Read the defect Pareto by part family too: a fix on one part number often stops at its drawing.
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