NCR (Non Compliance Report):-
CTAS non-conforming product is bad for both CTAS as well as the vendors because if a Customer receives a defective product it hurts the buyer’s brand image. Non-Compliance Reports (NCR) are directly integrated into all quality issues found by the buyer’s team in the head office A NCR is a step -by- Step process of determining a problem’s root, cause, implementing the appropriable corrective action, and preventing reoccurrence. This process follows the problem using the 8D solving methodology.
The Eight steps of the 8D Methodology
There are two scenarios to issues NCR | 8D CAP requests.
SCENARIO 1: This will occur after a factory as failed a final inspection & if a QA finds defective product or poor manufacturing indicators on the line then they will request the factory QC management to Submit 8D problem solving form to CTAS QA out lining the issues found and corrective action to be taken and all NCR reports will be received by the CTAS QA team. If the corrective action is deemed appropriate the NCR will be closed & if the report requires more work and detail then it will be re- assigned. The factory must ensure timely submission of all NCR and 8D problem solving forms.
SCENARIO 2: If a defective product is found by a CTAS QA then he will review the results of the audit, and make a decision whether or not a NCR should be required. A notification will be sent to the factory out lining the Po number, style description, and inspected Quantity. The notification will also include the defects that need corrective actions. Once submitted the factory must follow the 8D problem solving form & CTAS will determine the root cause and corrective action plan for each factory & they must complete additional 8D forms and attach them to the NCR report with in CTAS.
What is 8D example? The 8D methodology is a structured and systematic approach to a problem solving mechanism from. By solving example its clear that it not only identifies a problem but also recognizes the weaknesses in the system. Analysis of an 8D report example prevents future occurrences of similar issues.
CAP (CORRECTIVE ACTION PLAN)
This is a document that is used in quality management that outlines a set of steps for addressing issues and gaps in business operations a process that could negatively impact the business. It describes the approach for resolving an issue that interferes with reaching company goal.
MINIMUM REQUIREMENT OF QA HIRING: -
A new QA will undergo 90 days observation and training to ensure each factory has pertinent knowledge of buyer’s standards, inspection techniques and can instruct the vendor’s quality personnel. The primary function of the QA is to review buyer’s production for both in-line and final shipping quality. The auditor is required to complete 3 months start up and training period to demonstrate his auditing skills and the ability to discern by quality standard.
FINAL AUDIT PROCESS
The final inspection is the last chance to catch defective product before shipping to the destination country & it is critical that 100% of outbound P.O’s are audited to ensure product conforms to all buyer’s standards. CTAS’s electronic software will simplify the final audit by utilizing tablets that are given to all the QA personnel to record and submit the audit.
Audit work area must be clean, dry organized and quiet, preferably away from the production floor Overhead (day-light) (D65) lighting is required illumination should be minimum of 1078 lux.
SAMPLE SIZE: -
Determines the number of samples to pull as per size. Divide the number of pieces per size by the total order quantity, and then multiply by the sample size. The total number of pieces should add up to the sample size.
FOR EXAMPLE: -
Single color, single purchase order PO quantity 1200 pieces.
Sample size 32 Pieces.
Pull the number of samples that was calculated, then count the number of units in each carton from which garments are sampled from & compare number of units in carton against information on the OCL. Both quantities must match. Compare UPC information against information on the OCL and if visible, compare UPC size to garment size using the clockwise inspection method to deduct defects.
When a defect is found it must be marked immediately however the inspection of the garment must continue until the whole garment has been reviewed. The final defect classification will be according to the most critical defect found. Place the defective garment to the size. Always complete the audit even if the reject number is exceeded, inspect to complete sample size.
Once the QA has inspected all units and recorded all defects. The QA will view the total defects count and view the audit disposition and calculate if the audit passed or failed. Based on an AQL Level set. If shipment rework: vendor must inspect 100% and re audit prior to ship and notify the factory is necessary.