A rejection recorded and forgotten meets you again next lot. Here every non-conformance is captured as a material or line rejection, tagged with a defect code and Pareto-ranked; a major NCR escalates into a structured 8D — D1 team through D8 close — and the CAPA amends the FMEA and control plan so the defect is designed out, not just swept up.
A rejection is raised the moment inspection dispositions a lot RJ — everything after is containment, root cause and prevention. Defect codes carry the non-conformance from rejection to 8D and back to the FMEA.
Incoming inspection ties to the store receipt, so when a received lot fails, the material rejection is raised against the actual GRN line — not a fresh form. It is tagged with a defect code and the supplier, and the rejected quantity moves stock rather than staying a note. Because every material rejection carries the supplier and the defect, supplier-claim reporting and supplier defect trends fall out of daily work instead of a month-end reconciliation.
A part scrapped at an operation is a line rejection, recorded against the work order and the process that produced it — so rejection is attributed to a real operation and work centre, not a vague "shop floor". For assemblies, child-part rejection captures which component failed inside the built-up part. The result is rejection you can slice by process and work centre, and a defect-vs-work-centre picture that tells you where a problem actually lives.
Every rejection is recorded against a defect code from one shared defect master, so incoming and in-process non-conformance analyse together. The rejection Pareto then ranks the loss by defect, by process and by part — and the top two or three bars usually carry most of the cost. That is where the 8D goes first. Consistent defect codes are also what let a defect on the line trace back to the failure mode that predicted it in the FMEA.
A major NCR — or a customer complaint escalated from Fast Complaint — opens a structured 8D: D1 team, D2 problem, D3 containment, D4 root cause, D5 permanent corrective action, D6 implement, D7 prevent recurrence, D8 close. The CAPA is driven through change management, which amends the FMEA (RPN re-evaluation) and the control plan and, where required, triggers a PPAP re-submission. Not everything is scrap: a recoverable lot goes to rework and returns as corrected stock, and a usable-as-is lot is dispositioned Accept-Under-Deviation through an approved concession.
The incoming/supplier NCR raised against the GRN line, tagged with defect code and supplier, driving stock disposition and supplier-claim reporting.
In-process rejection booked against the work order and process, with child-part rejection for assemblies and a defect-vs-work-centre view.
One defect-code catalogue shared across rejection, 8D and FMEA — the common language that links a floor defect back to the failure mode.
Rejection ranked by defect, process and part, so the vital few losses stand out and the 8D team works on what actually costs money.
A structured 8D report from team and problem through containment, root cause, permanent corrective action, prevention and verified close.
Accept-Under-Deviation for a formal, bounded use-as-is decision, and rework process sheets that return corrected stock instead of scrap.
Most systems store a rejection quantity and a reason typed in a box. A reason is not a root cause, and it prevents nothing. Here is the difference — and for the wider picture, read what is quality management software?
Material rejection is the incoming/supplier NCR: a received lot fails incoming inspection against its GRN, so a rejection is raised against that GRN line and tagged with a defect code and the supplier, which then drives supplier-claim reporting. Line rejection is the in-process NCR: a part is rejected during production against its work order and process, with child-part rejection for assemblies. Both dispositions are captured with the same defect codes so incoming and in-process non-conformance analyse together.
A significant or recurring NCR — a material rejection, a line rejection, or a customer complaint from Fast Complaint — is opened as a structured 8D report. It runs D1 team, D2 problem description, D3 containment, D4 root cause, D5 permanent corrective action, D6 implement and validate, D7 prevent recurrence and D8 close. The 8D captures the CAPA, and the corrective action is driven through change management so it amends the FMEA and control plan rather than staying a one-off fix.
A rejection Pareto ranks non-conformance by defect code, by process and by part, so the few defects causing most of the rejection are visible instead of anecdotal. Because material rejection and line rejection share one defect-code catalogue, the Pareto pulls incoming and in-process rejection together and points the 8D team at the defects worth a permanent corrective action first.
A deviation or concession is a formal, time or quantity bound acceptance of non-conforming product. When a lot is not fully conforming but can still be used, it is dispositioned Accept-Under-Deviation (AD) through an approved deviation request rather than Rejected (RJ) or Accepted (AC). The concession is recorded and auditable, so a conscious engineering decision replaces an off-the-record "use as is".
Defect codes are the common language of the closed loop. A defect detected at inspection is recorded against a defect code; that code tags the material or line rejection, carries into the 8D, and traces back to the failure mode in the FMEA. So a defect on the line points to the FMEA row that predicted it, and the CAPA feeds an FMEA RPN re-evaluation — rejection, 8D and FMEA all speak the same defect codes.
Live demo of the rejection-to-8D loop — material and line rejection, defect Pareto, 8D and CAPA into the FMEA — on a defect like yours. Cloud or on-premise, no generic slideshow.
