Non-Conformance / Rework SOP

This procedure defines how Blitzpanel identifies, tags, records, dispositions, and closes out non-conforming work found on control panels, subpanels, and enclosures at any point from fabrication through final test.

It exists to keep non-conforming material from shipping, to make disposition and rework decisions consistent and defensible, and to feed real root-cause data back into the shop so the same defect does not repeat.

It applies alongside the acceptance criteria in the Quality Control (QC) Standard; this SOP governs what happens once an item fails one of those criteria.

Applies to any suspected or confirmed non-conformance discovered on in-process or finished work, including workmanship, wiring/termination, labeling, dimensional, component, and functional/electrical test failures.

Covers stop-work and tagging at discovery, opening and classifying the Non-Conformance Report (NCR), disposition (use-as-is, rework, or scrap), rework execution and re-inspection, and root-cause/corrective-action capture and closure.

Does not cover incoming-material receiving inspection (component defects found before kitting/issue) or post-shipment field failures, which are handled as returns (see Warranty / RMA Handling SOP). TODO: confirm whether supplier-caused NCRs discovered pre-kitting route through this SOP or a separate receiving-inspection process.

Non-conformance (NC) — any condition that deviates from the released drawing, BOM, schematic, or an applicable Blitzpanel Standard.

NCR — Non-Conformance Report: the record that documents an NC from discovery through disposition, rework/re-inspection, and closure.

Disposition — the formal decision made on a non-conforming item: Use-As-Is, Rework, or Scrap (and, for supplier-supplied material, Return-to-Supplier).

Use-As-Is (UAI) — the item is accepted without corrective work because Engineering has determined the deviation does not affect fit, form, function, safety, or the panel's UL508A listing.

Root cause — the underlying process, training, tooling, design, or supplier condition that allowed the non-conformance to occur, as distinct from the immediate/apparent cause.

Role	Responsibility
Employee who discovers the NC	Stops work on the affected item, segregates it, applies a hold tag, and notifies QC before continuing.
QC Inspector	Opens and owns the NCR record, classifies severity, coordinates disposition routing, and signs off re-inspection.
Engineering	Reviews Major/Critical NCRs, approves or denies Use-As-Is dispositions, and issues rework instructions when the released drawing/spec is affected.
Production / Rework Technician	Performs approved rework using calibrated tools and documented instructions; does not perform undocumented "quick fixes."
Quality Manager / Material Review Board (MRB)	Approves Scrap and Use-As-Is dispositions above the defined threshold and signs off closure of Critical NCRs. TODO: confirm MRB composition and dollar/severity threshold requiring MRB review.
Purchasing	Issues a supplier corrective action request (SCAR) and coordinates return/credit for supplier-caused non-conformances.

Hold tags (physical, job/serial-traceable) for segregating non-conforming items in WIP or finished-goods staging. TODO: link/attach the current hold-tag template and confirm tag stock location.

NCR log / system of record for opening, routing, and closing NCRs, including photo attachment capability. TODO: name the system of record (spreadsheet, QMS module, or CRM add-on).

Calibrated rework tools consistent with the original operation (torque driver, crimp tool, wire stripper set) and, where electrical work is reworked, the hi-pot/insulation-resistance tester used for re-test.

Root-cause / corrective-action (CAPA) template for structured root-cause capture (e.g., 5-Why or fishbone worksheet). TODO: attach the standard CAPA template.

6.1 Identification & tagging

Any employee who discovers a suspected non-conformance MUST stop work on the affected item immediately and MUST NOT continue the operation in progress on it.

Physically segregate the item from conforming WIP and attach a hold tag showing the job/serial number, date, discoverer's name, and a brief description of the suspected defect.

Notify the QC Inspector before any further work is performed on the same panel or job, including work unrelated to the tagged item.

Do not perform informal, verbal-only, or undocumented corrective work on a tagged item; all corrective action MUST go through the disposition process in §6.3.

6.2 NCR record creation & classification

The QC Inspector opens an NCR record and assigns a unique NCR number within TODO: define required turnaround (e.g., same shift/24 hours) from hold tag to NCR open.

Record what was found, where on the assembly, how it was discovered (in-process inspection, final QC, functional test, customer complaint), the job/traveler number, and quantity affected.

Classify severity as Critical, Major, or Minor using the definitions in the Quality Control Standard §4.6, and photograph the non-conformance when practical.

Route the NCR per severity: Minor may be dispositioned by the QC Inspector alone; Major and Critical MUST be routed to Engineering and, above threshold, to the MRB. TODO: confirm the Major/Critical routing threshold and required response time.

6.3 Disposition

No panel or assembly with an open NCR may resume production or ship until a disposition is recorded and, for Major/Critical NCRs, approved by the required reviewer.

Use-As-Is: Engineering documents the specific rationale confirming no impact to fit, form, function, safety, or the UL508A listing before the item is released back to the flow.

Rework: Engineering or QC issues written rework instructions referencing the released drawing/BOM and the specific non-conformance; proceed to §6.4.

Scrap: the item is removed from WIP/inventory and its cost is logged against the job or a quality-cost account; root cause is still required per §6.5. TODO: define scrap authorization threshold and required approver.

Return-to-Supplier: for supplier-supplied non-conforming material, Purchasing issues a SCAR and coordinates replacement, credit, or return freight.

6.4 Rework instructions & re-inspection

Rework MUST be performed only against the written instructions from §6.3, using calibrated tools and the procedure applicable to the original operation (e.g., torque, crimp, termination, relabeling).

Reworked items MUST be re-inspected against the same acceptance criteria applied to the original build, and re-tested (continuity, dielectric/hi-pot, functional) whenever the rework could affect a previously passed test (see Functional Test / Power-Up Test SOP).

The QC Inspector records the re-inspection/re-test result on the NCR before the hold tag is removed; the hold tag may be removed only by QC after a passing result.

If rework does not bring the item into conformance, re-open disposition at §6.3 rather than repeating undocumented rework attempts. TODO: define maximum rework attempts before mandatory scrap/engineering escalation.

6.5 Root-cause capture & closure

Every Major and Critical NCR, and any Minor NCR meeting the shop's recurrence threshold, MUST have a documented root cause distinct from the immediate/apparent cause. TODO: define the Minor-NC recurrence threshold that triggers mandatory root-cause analysis.

Identify contributing factors (process, training, tooling/calibration, drawing/BOM error, or supplier) and assign a corrective action owner and due date to prevent recurrence.

Any NCR affecting a UL508A-listed characteristic (SCCR, overcurrent protection, listing marks) MUST be reviewed and signed off by Engineering/Quality before closure, regardless of disposition. TODO: verify against Blitzpanel's UL Follow-Up Service procedure whether listing-affecting NCRs require notification to UL.

Close the NCR only after disposition, rework/re-inspection (if applicable), and the root-cause/corrective-action fields are complete; update the NCR log status to Closed.

NCR record: unique number, description, discovery method, severity classification, disposition, approver(s), and closure date.

Rework instructions and re-inspection/re-test results, cross-referenced to the job traveler (see Job Traveler / Document Control SOP).

Root-cause and corrective-action record, including assigned owner, due date, and verification that the action was implemented.

Retention period for NCR and rework records. TODO: set retention policy, and confirm alignment with UL508A Follow-Up Service record-retention requirements.

Quality Control (QC) Standard, Functional Test / Power-Up Test SOP, UL508A Compliance Documentation SOP, Job Traveler / Document Control SOP.

UL508A — Standard for Industrial Control Panels (listing basis for disposition decisions affecting SCCR or listing marks). TODO: verify exact clause references before citing.

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