Exide Leclanche Energy Pvt Ltd. DOC. NO.

: ELEPL/III/PD/QAD-08

Control of Non-Conforming Products Section No.

Page 1 of 10
PD/QAD-12

Control of Non-Conforming Products

Asst. Manager REVISION

Head - Quality MR CONTROLLED
Quality 00 31/12/2021
PREPARED BY CHECKED BY APPROVED BY CONTROL STATUS STATUS DATE
 Exide Leclanche Energy Pvt Ltd. DOC. NO.: ELEPL/III/PD/QAD-08

Control of Non-Conforming Products Section No.

Page 2 of 10
PD/QAD-12

Table of Contents

1. Purpose ....... ……………………………………………………………………………………3

2. Scope .......... ……………………………………………………………………………………3

3. Responsibility………………………………………………………………………………....3

4. Definition………………………………………………………………………………………...3

5. Procedure……….………………………………………………………………………………5

6. Procedure Performance Indicators…….………………………………………………….10

Asst. Manager REVISION

Head - Quality MR CONTROLLED
Quality 00 31/12/2021
PREPARED BY CHECKED BY APPROVED BY CONTROL STATUS STATUS DATE
 Exide Leclanche Energy Pvt Ltd. DOC. NO.: ELEPL/III/PD/QAD-08

Control of Non-Conforming Products Section No.

Page 3 of 10
PD/QAD-12

1. PURPOSE:

1.1 To define control procedure for identification, control and disposition of non-
conforming products and suspect material.

1.2 To ensure that non-confirming products and suspect material are not moved to next
operation.

1.3 To define the responsibility for review and authority for disposition of non-
confirming products and suspect material.

1.4 Control of Rework and rejected products.

2. SCOPE:

This procedure covers all manufacturing line and other areas of ELEPL.

2.1 NC Product Control including handling, storage, identification, and disposition of

Product at ELEPL.
2.2 Deviation Approval

3. RESPONSIBILITY:

3.1 The Process owner is responsible for implementing this Procedure

3.2 The Procedure can be amended by Process owner

3.3 This Procedure is reviewed & issued by Quality Department.

4. DEFINITION:

4.1. Non-conformity

Any deviation from Quality requirements of that process.

4.2 Non-conforming Product:

A product that does not conform to specified Quality requirements.

It is classified in five categories:

i. Rework:

A non-conforming product which can be reprocessed to make it suitable

to conform to the requirements.

Asst. Manager REVISION

Head - Quality MR CONTROLLED
Quality 00 31/12/2021
PREPARED BY CHECKED BY APPROVED BY CONTROL STATUS STATUS DATE
 Exide Leclanche Energy Pvt Ltd. DOC. NO.: ELEPL/III/PD/QAD-08

Control of Non-Conforming Products Section No.

Page 4 of 10
PD/QAD-12

ii. Repair:

Repair is an action on non-conforming product to make it acceptable for

intended use.

iii. Scrap:

A non-conforming product which can not be reprocessed for

conformance to requirements.

iv. Deviation:

Permission to use or release a product in which some

parameters/specifications do not conform to specified Quality
requirements but will not affect the functional requirement of final product.

v. Suspect Material or Product

Any material or product where the inspection and test status are
uncertain or not known.

4.3 “Drawing” is a well drawn data by hand or by computer which clarifies contents
and structure of product, tooling, devices, layouts, packing, machine parts, and
sub assemblies.

4.4 “User Departments” are the Departments which use the drawings for their
working.

4.5 “Engineering standards” are the standards made by product & process
engineering for making and inspecting various components.

Asst. Manager REVISION

Head - Quality MR CONTROLLED
Quality 00 31/12/2021
PREPARED BY CHECKED BY APPROVED BY CONTROL STATUS STATUS DATE
 Exide Leclanche Energy Pvt Ltd. DOC. NO.: ELEPL/III/PD/QAD-08

Control of Non-Conforming Products Section No.

Page 5 of 10
PD/QAD-12

S.NO. RECORD /
ACTIVITY RESP.
CROSS REF.
5.1 PROCEDURE FOR NC PRODUCT CONTROL

5.1.1 IDENTIFICATION & STORAGE:

A non-confirming product is labelled/marked as follows: Prod. Designated
Labels
a) Reject/Scrap - ELEPL/IV/FR/PRO-19

b) Pass/OK - ELEPL/IV/FR/PRO-18

c) Rework/Hold ELEPL/IV/FR/PRO-17

5.1.2 N.C. Product is stored in separately defined area. Respective Designated

process area
owner

5.1.3 Colour Coding for storage:

Shift Sup. / Tags
Reject - Red colour Respective PCD
Pass - Green colour
Hold/Rework - Yellow colour

5.1.4 This procedure defines the control of NC product for

Material processed at ELEPL.
Material processed by Supplier (As per Procedure
ELEPL/III/PD/QAD-03)

5.2 MATERIAL PROCESSED AT ELEPL

5.2.1 Detection
The NC material is detected during Job setting, Respective -----
Regular production Audit, During subsequent operation Line supervisor
Initial product / New product production
When inspection equipment/gauge is found out of
calibration

5.2.2 Identification
The NC material is identified by appropriate labels as Respective ------
mentioned in step 5.1. Labels are put by Supervisor

Asst. Manager REVISION

Head - Quality MR CONTROLLED
Quality 00 31/12/2021
PREPARED BY CHECKED BY APPROVED BY CONTROL STATUS STATUS DATE
 Exide Leclanche Energy Pvt Ltd. DOC. NO.: ELEPL/III/PD/QAD-08

Control of Non-Conforming Products Section No.

Page 6 of 10
PD/QAD-12

operator/auditor/shift supervisor/setter as the case may

be.

5.2.3 Recording
The quantity of NC material is recorded in setting Shift Sup. / Respective
approval check sheet/Daily rejection sheets Respective setting approval
operator check sheet/
/Daily rejection
sheets
5.2.4 Disposition
 The disposition of NC material identified by the Shift Sup. / --------
operator/auditor/setter is done in concurrence with Respective
In-charge
production & or quality supervisor. NC material is
disposed as follows:

5.2.4.1 Scrap Disposition & control

 Scrap materials are verified by Production & sent to Shift Sup. / Rejection
earmarked area for scrap. Respective Record
In-charge ELEPL-IV-FR-
 Quantity of scrap is recorded in daily rejection & after
PRO-13
disposition by QA, production will generate scrap
note and hand over to MP&L with approval from Scrap Note
Manufacturing Head. ELEPL-IV-FR-
MPL-02

5.2.4.2 Rework Disposition & control

- Rework material is reprocessed in following Shift Sup. /

manner. Respective SAP
 Hold material in temporary storage, with Production
identification label near the line, it is reprocessed at in charge
the end of the shift & Recorded in SAP/log.
 In case re-processing of rework is not possible with
same Shift then rework will be done at end of
Production order.
 Recording of rework piece’s fault wise is done at
respective location and after rework processing Operator PQCS
inspection/verification to be done against original rework Parts
specifications.

- Rework failure mode risk analysis to be PFMEA &

potentially identified in PFMEA and control control
Process
addressed in control plan. Plan
Engg. & CFT Tag
ELEPL/IV/FR/PR

Asst. Manager REVISION

Head - Quality MR CONTROLLED
Quality 00 31/12/2021
PREPARED BY CHECKED BY APPROVED BY CONTROL STATUS STATUS DATE
 Exide Leclanche Energy Pvt Ltd. DOC. NO.: ELEPL/III/PD/QAD-08

Control of Non-Conforming Products Section No.

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PD/QAD-12

- Record to be maintained of disposition of Production O-17/ Rejection

reworked product including quantity, disposition, Record
ELEPL-IV-FR-
disposition date, and applicable traceability PRO-13
information. & Traceability
- Ensure the customer specific requirement for
rework (if specified)

5.2.4.4 Disposition of material with Deviation

Pieces moved to next operation under deviation are Shift Sup. / Procedure for
controlled as per procedure for deviation. QA Deviation
(ELEPL/III/PD/QAD-02) ELEPL/III/PD
/QAD-02

5.2.4.5 Disposition of Lot for Sorting

After sorting by Concerned dept., material is identified Shift Sup. /
appropriately such as OK/rework/scrap/deviation. This is Respective in ------
treated as per steps shown above. Material tagging to be charge
done accordingly.

In case of Product Audit , if any discrepancy found

100 % material to be check for particular defect for same Product Audit
production order. Quality Auditor report
(ELEPL-IV-
FR-QAD-29)

5.2.4.6.1 In case of non-conforming product, ------- ------

such as rework, scrap, or material under deviation it is
handled as per Step 5.4

Asst. Manager REVISION

Head - Quality MR CONTROLLED
Quality 00 31/12/2021
PREPARED BY CHECKED BY APPROVED BY CONTROL STATUS STATUS DATE
 Exide Leclanche Energy Pvt Ltd. DOC. NO.: ELEPL/III/PD/QAD-08

Control of Non-Conforming Products Section No.

Page 8 of 10
PD/QAD-12

Analysis & Countermeasure of non-conforming products-

S.NO. RECORD /
ACTIVITY RESP.
CROSS REF.

5.2.5 Analysis & Countermeasure

 Review and analyse the non-conformities. Respective Designated formats

Takes appropriate correction/corrective/ action DH
as per procedure for Problem solving action
No. ELEPL/III/PD/QAD-08, Section PD/QAD-
11

5.3 Material processed by Supplier

5.3.1  Detection of Non-conformity:

 The non-conformity in any purchased

material can be detected at following stages: -

a) Receiving Inspection

b) During Manufacturing Processes

5.3.1.1 Non-Conformity at Receiving Inspection Stage

After the material has been inspected as per Respective ELEPL-IV-FR-QAD-

respective Receiving Inspection Procedures, the Engg. 11 IGI Rejection Log
respective inspection in-charge posts NC material Incoming Book & SAP
in SAP. NC material is identified by putting
`REJECT' labels on material.

Asst. Manager REVISION

Head - Quality MR CONTROLLED
Quality 00 31/12/2021
PREPARED BY CHECKED BY APPROVED BY CONTROL STATUS STATUS DATE
 Exide Leclanche Energy Pvt Ltd. DOC. NO.: ELEPL/III/PD/QAD-08

Control of Non-Conforming Products Section No.

Page 9 of 10
PD/QAD-12

5.3.1.2 The NC material is stored in separately marked Stores As per stores

areas as per Identification and Storage place procedure

5.3.1.3 This NC material is disposed as per procedure for Store / SQA As per stores &
receiving inspection & Stores / SQD Receiving
Inspection procedure
(ELEPL/III/PD/QAD-03)

5.3.1.5 Non-Conformity in Input material detected

during Manufacturing Process
5.3.1.5.1 When NC material is detected after the material has Incoming To be discussed in
been issued to shop and put into the production Engg. DWM.
process the concerned production keeps the
material duly identified and informs Incoming
Quality.

Further action is to be taken as per SQD procedure.

5.3.1.5.2 Scrap/Rework pieces are recorded in Supplier Respective Supplier rejection log
Rejection Sheet and OK material is released for Incoming
next process. Engg.

5.4 PROCEDURE FOR DEVIATION APPROVAL

RECORD /
S.NO. ACTIVITY RESP.
CROSS REF.

Any material / product for which Deviation Respective ELEPL/III/PD/QAD

5.4.1 approval is required, to be handled as per DH -02
Deviation procedure ELEPL/III/PD/QAD-02

DESTRUCTIVE TESTING SCRAP

5.5 Engg. QA ------
CONTOL

Non-conformity can be detected at following

stages

Asst. Manager REVISION

Head - Quality MR CONTROLLED
Quality 00 31/12/2021
PREPARED BY CHECKED BY APPROVED BY CONTROL STATUS STATUS DATE
 Exide Leclanche Energy Pvt Ltd. DOC. NO.: ELEPL/III/PD/QAD-08

Control of Non-Conforming Products Section No.

Page 10 of 10
PD/QAD-12

- Material Checking at incoming

- Material checking in-process

After destructive test, put scrap material in red

5.5.1
bin at lab

Fill Scrap note (SAP) and Scrap material Engg. ELEPL-IV-FR-MPL-

5.5.1.1 02
handed over to stores (MP&L) Incoming

5.6 PROTOTYPE LAB SCRAP CONTROL

Scrap note to be filled by Proto-in-charge for Proto In- ELEPL-IV-FR-MPL-

the declared scrap and hand over to MP&L. charge 02

6. PROCEDURE PERFORMANCE INDICATOR:

6.1. Customer complaint.

6.2. Rejection%

6.3 Rework%

Asst. Manager REVISION

Head - Quality MR CONTROLLED
Quality 00 31/12/2021
PREPARED BY CHECKED BY APPROVED BY CONTROL STATUS STATUS DATE