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  • Systematic Corrective Action Processes
Systematic Corrective Action Processes

If CAPA is required, a Supplier will appoint a qualified representative within its organization who has the responsibility and authority to resolve quality matters. This person(s) must be of a level to effectively interact with their senior management and with Novelis to drive resolution of quality issues. The representative must provide a written CAPA report in a timely manner.

Novelis determines whether or not a CAPA should be requested based on the seriousness or impact of the issue on the quality of Novelis product. The Novelis CAPA system facilitates the prompt investigation, correction, and prevention of non-conformances. Upon receipt of a CAPA request, Suppliers shall respond using an 8D format or similar (see definition below). Novelis will provide the Supplier with a specific due date to complete the CAPA process.

Suppliers are expected to maintain a corrective action program with their Suppliers.

Eight Disciplines (8D)

The Eight Disciplines (8D) model is a problem solving methodology to identify, correct and eliminate recurring problems. It is highly regarded for product and process improvement.

8D establishes a permanent corrective action based on statistical analysis of the problem, and focuses on the origin of the problem by determining its root causes. After planning, Suppliers are expected to execute each of the eight stages.

D0 Planning Stage – Plan for solving the problem and determine the prerequisites. Additionally, collect data of the symptoms and determine if there is any emergency response needed.

D1  Establish the Team – Form the team of people with product/process knowledge and define the objectives.

D2  Problem Definition – Specify the problem and the impact by identifying in quantifiable terms the who, what, where, when, why, how, and how many (5W2H) for the problem.

  • Problem Example: Novelis received the incorrect hardener
  • Impact Example: The wrong hardener caused the scrap of 8 full ingots

D3  Develop Interim Containment Actions (Protect the Customer) – Define and implement short-term containment actions to isolate the problem from any customer.

  • Example: All incoming material from Hardener Supplier X will be 100% inspected before being received into inventory

D4  Root Cause Analysis Action Plan – What is the teams plan to perform the root cause analysis. Who is going to do what? When will the do it? What are the expected outcomes?

Root Cause Analysis – Identify and Verify Root Causes (RCA) – Identify all applicable causes that could explain why the problem occurred. Also, identify why the problem was not noticed at the time it occurred. All causes must be proven or verified.

  • Example: The Supplier mislabeled the hardener at their facility which led it to be sent to Novelis

Note: A few examples of root cause analysis tools include Cause and Effect, FTA, FMEA and 5 Whys. The team is responsible for choosing the best tool for the issue.D5  Develop Corrective Actions – Develop the long term corrective actions.

  • Example: The Supplier will provide a material certification with each shipment. Additionally, the Supplier will change the packaging of their product (different color bags based on material family) so that the label is not the only way to determine what material is in the bag. Lastly, the Supplier will change their labeling process to ensure the proper labels are placed on the bags.

D6  Implement and Verify Long Term Corrective Actions – Define and implement the corrective actions and verify they have not caused an additional problem.

  • Example: The Supplier changed colors of their bags to reflect different materials. However, the new color for Novelis material matches the bag color from another Supplier with a different material.

D7  Prevent Recurrence – Control Plan – Add controls to prevent recurrence and ensure if the problem happens again, it is more likely to be identified.

  • Example: Novelis will send a sample from each shipment from Supplier X for independent analysis at the Suppliers cost for at least 1 year. At that time the data will be reviewed to determine if this step is still required or it can be eliminated or the frequency lowered.

Prevent Recurrence – Review Documents and Systems and Update – All relevant documents should be updated to reflect the corrective actions.

  • Example: The process flow will need to reflect gathering a sample to be sent out for evaluation. Also, work instructions need to be updated to reflect the new bag colors and what to do with this material.

D8  Congratulate the Team – Recognize the collective efforts of the team. Make sure the team knows their successful work is appreciated.

Other Corrective Action Processes

8D is the tool of choice for Novelis. However, any effective tool used by a Supplier is acceptable, provided it answers all the questions in 8D. A Supplier may copy and paste responses from their form to Novelis 8D form. Other commonly used tools include 6 Sigma, A3, 7 Step and FTA.

 

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