What procedure should you follow when you encounter a quality problem?

Question

What procedure should you follow when you encounter a quality problem?

Answer

The procedure to follow is not the same everytime. It depends on the following aspects, which the customer must consider:

• Is the material replaced for the same order, or is a new order issued/released?
• Is the waste considered among consumption or not? If the entire container has to be unwrapped and it is an exceptional event, you may not count it. If, however, the defect is chronic, it must be considered as consumption.
• Is the entire container discarded or just some pieces?

The procedure you need to follow is the following:

1. The material is received and the card is declared Full;
2. When the material is taken to Quality control for the inspection, the card is Blocked with "quality control" reason;

CASE 1 - The material is complied

1. The card is Unlocked and placed at the customer's site.

CASE 2 - The container must be completely discarded and the supplier replaces the material

1. The card remains Blocked, with "quality gap, waiting for restoration" reason;
2. In a system external to KanbanBOX, the supplier is asked to restore the material;
3. When the new material arrives, the card is reprinted and applied to the new container;
4. The card is Unlocked and placed at the customer's site.

CASE 3 - The container must be completely discarded and a new order must be issued

1. The card is Unlocked and set to Full (setting the quantity to zero if you do not want to track consumption);
2. In this way, a new card is generated and the recovery cycle starts again;
3. Eventually, a note indicating that this is a recovery can be added to the card.

CASE 4 - The container is to be partially discarded

1. The card is Unlocked and placed at the customer's site. No action is required from a kanban point of view. The waste is considered in the consumption.