Creating Nonconformance Routings

When the shop floor operator identifies a scratch in the bicycle frame, they must repair it to ensure it can continue in the production process and eventually be shipped according to the defined quality standards.

When the operator logs a nonconformance (NC) code against a shop floor control (SFC), the SFC can remain at the current operation for local repair. If this is not possible, the SFC can be automatically moved, for example, based on the chosen NC code, or manually (by the operator) to the next step where further actions can be initiated. Afterwards, the SFC can return to the default manufacturing process.

When you use Nonconformance Disposition Routings, you are able to assign Special Routings, Disposition Function Routings, or NC Routings to NC codes to control the flow of SFC numbers. When an operator logs an NC in the production operator dashboard (POD), the system sends the nonconforming SFC number to the associated routing. If you associate more than one routing with an NC code, the system displays a list with all options. The operator selects an option in the list to send the SFC number to that routing.

Once the nonconformance has been resolved in the disposition routing, it returns to the production routing to continue the rest of the manufacturing process.

You can create routings to specifically detect and handle nonconformances. To do this, you can use two approaches:

• Use In-routing Rework Loops to handle nonconformances within one routing.
• Use Nonconformance Disposition Routings to handle nonconformances in separate routings.

If you want to handle nonconformances within a standard production routing, you can create a routing with a loop of operation activities to keep the nonconformance processes within itself.

For example, the graphic below shows an example of using an in-routing rework loop to allow test, analyze, and repair actions without the SFC being moved to a separate routing.

In the example, the production routing has the operation activities Final Inspection, Analyze, and Repair that form a loop. When an SFC fails the quality test at TEST, the production operator logs an NC code and selects ANALYZE as the next operation activity. The SFC goes through ANALYZE and REPAIR, during which the production operator can log more NC codes to record information about the analysis and repair. After the repair, the SFC is tested again at TEST. If the test succeeds, the production operator selects PACK as the next operation activity.

If you want to handle nonconformances outside of a standard production routing, you can create one or more separate routings to process nonconformances. A nonconforming SFC can be sent, or dispositioned, to these routings and eventually returned when its nonconformances are resolved.

If you want to disposition an SFC when you log a specific NC code, you can assign one or more routings to this NC code using the Manage Nonconformance Codes application. After logging this NC code, the production operator can choose to disposition this SFC to one of its assigned routings. Only routings of the type NC Routing, Special Routing, or Disposition Function Routing can be assigned to an NC code as Nonconformance Disposition Routings:

• NC Routing: Use this routing to process nonconformances.
• Special Routing: Use this routing to perform special operations. Please note that the difference between NC Routing type and Special Routing type is conceptual. Functionally, they behave the same, so you can achieve the same processes with either type. The difference in naming helps you organize your routings.
• Disposition Function Routing: Use this routing to perform single disposition actions, such as returning or scrapping.