Resource Library/Product Integrity and Aerospace Requirements/Nonconforming Product Segregation Checklist
Nonconforming Product Segregation Checklist
Walk the floor and the hold area with five short checklists and a reconciliation sheet: every nonconforming and suspect part identified where it was found, held where it cannot be used, matched to its record, scrapped beyond recovery, and released only on a signed disposition.
- Word
- fillable PDF
- Worked example
- Your logo on it
- Aegis Insights
Page 1 of the PDF. Every resource includes a fully worked example.
The problem it solves
Nonconforming product rarely escapes because someone decided to ship it. It escapes because a tag fell off, a box sat on a bench for a shift with no tag at all, a scrapped part went back in a tote with good ones, or the cage held more parts than the log knew about. Audits find the same things: hold areas with untagged items, tags that do not match the NCR, scrap that is still perfectly usable, and suspect parts sent back to the supplier who sent them. This checklist turns segregation into a walk with a record: what to check where the problem is found, in the hold area, at the scrap bin, on the suspect shelf and at release, plus a sheet that reconciles every container in the cage against the log.
Who uses it
Production supervisors, inspectors and the hold-area custodian who do the walk; quality engineers and the quality manager who act on what it finds; internal auditors sampling the nonconforming product process.
When
Once a week in the hold area, every time a new area or shift starts holding product, before every MRB and before a customer or registrar audit. Checklist 1 also works as a spot check on any shift.
Free to use, change and copy, in your own organization or with your clients; add your own logo, keep the Aegis credit. Part of: MRB and Nonconformance Kit. Clause references: 8.7, 8.7.1, 8.7.2 (with 8.1.4, 8.5.2, 8.5.4) (numbers only; use your own licensed copy of the standard).
A management aid, not certification or a registrar audit. Using it does not by itself show conformity to AS9100D or any other standard.
How to put it to work
Chapters of our free guides that use this tool.
- The kitThe MRB and Nonconformance Kit Handbook, chapter 2
- The workflowThe MRB and Nonconformance Kit Handbook, chapter 3
- Identification, segregation and the hold areaThe MRB and Nonconformance Kit Handbook, chapter 6
- Running the material review boardThe MRB and Nonconformance Kit Handbook, chapter 9
- RecordsThe MRB and Nonconformance Kit Handbook, chapter 16
- The rhythmThe MRB and Nonconformance Kit Handbook, chapter 17
Related resources
-
Workbook
Nonconformance Management Log
One line per NCR, from the moment it is found to the moment it is closed: the part, the requirement, where it was found, the disposition and who authorized it, customer approval, cost, the corrective action link and how long it has been open.
Excel · PDFFree by email -
Workbook
MRB Disposition Record and Log
One record per material review board case, from the evaluation to the signatures to the product action, and one log that ages every open case, tracks every customer authorization and flags any use-as-is or repair released without the approvals it needs.
Excel · PDFFree by email -
Checklist
Containment and Corrective Action Verification Checklist
Two checklists: one to confirm containment reached every suspect part, wherever it is, and one to confirm a corrective action is in place where the work is done and has worked, before anyone signs it closed.
Word · PDFFree download -
Kit handbook
The MRB and Nonconformance Kit Handbook
A complete, working system for nonconforming product in an aerospace shop: find it, tag it, hold it, contain it, decide on it with the right authority and the customer's authorization where the contract requires it, act on it, learn from it, and keep the hold area empty.
Word · PDFFree by email -
Template
Counterfeit Parts Prevention Plan
A written plan you adopt and edit: which parts and materials are at risk, where you may buy them, what your purchase orders flow down, what receiving checks by risk, how traceability is kept, and exactly what happens to a suspect part, from the shelf it goes on to who is told.
Word · PDFFree download -
Workbook
Shelf-Life Material Control Register
Every lot of sealant, primer, adhesive and other shelf-life material, with its expiry, any approved extension and the opened-container limit worked into one use-by date, a status that flags what to pull today, and a log of the fridge and freezer readings that keep it good.
Excel · PDFFree download
Need more than one resource, or not sure where to start? Book a complimentary 30-minute Aegis Quality Guidance Call. We'll find the tools that fit your situation and a sensible place to start. No sales pressure, no obligation.
These tools help you run the work by hand. When you want the whole picture of your quality system from the records you already keep, that's what the AeroAssure Audit Defense Pack and the IA9100 Transition Gap Analysis do.