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NCR

Turned shafts from a supplier have OD measurements outside tolerance. Customer already notified.

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NCR

Slag inclusions in welded joints confirmed by liquid penetrant testing. Night shift production lot.

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CAPA

Paint adhesion keeps failing after powder coating. Third time in 6 months, customer threatening cancellation.

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CAPA

Resin supplier has delivered late 4 of 6 orders causing $45K in lost production. Need formal corrective action.

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Fishbone

Injection molding scrap jumped from 2% to 9% after switching resin suppliers. Sink marks and flash.

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Fishbone

Cpk dropped from 1.8 to 0.9 on turned aluminum parts. Insert change last week may be the cause.

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5 Whys

Pneumatic press failed mid-shift, 45-min line stop. Second unplanned downtime this week.

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5S Audit

Monthly 5S audit for CNC machining cell. Focus: chip management, tool storage, coolant spills.

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5S Audit

Quarterly 5S audit of raw material warehouse. FIFO rotation, labeling, chemical storage, PPE usage.

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Raw Data

Break torque results for M8 bolts. 3 of 25 values below spec. Supplier has had prior rejections.

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