Corrective Action Requests (CAR) in Manufacturing 1.
Learn about Tex Moseri's use of CARs to improve quality at New Balance Athletic Shoe, Inc. 2.
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About Corrective Action Requests (CAR) in Manufacturing 1.
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Slide11Corrective Action Requests (CAR) Tex Moseri New Balance Athletic Shoe Inc.
Slide22What is a CAR? RSL failure document generated for: • Raw material and chemical failures • Manufacturing processes issues • Finished products failures • Customer complaints and product recalls
Slide33Completing a CAR? Include the following: • Vendor information • Description of failure • Reason for use and presence of substance(s) • Prior knowledge of substance on the RSL • Next steps to resolve the failure • Project leader to implement corrective action
Slide44Elements of a good CAR? • Chemical awareness & process understanding (Root cause) • Track, trace, and stop (Recall process) • Alternatives and process changes (Action plan) • Project leader and deliverables (Timelines)
Slide55CAR Example Issue: • CPSIA Lead failure > NB STD Investigation of the known: • Tracked back supplier manufacturing process • Tracked back all chemicals & pigments used • Tracked back previous RSL test reports • Tracked back production lot# / batch#
Slide66CAR Example Findings: • One Red pigment used without test record • XRF-gun screen testing • 3 rd party confirmation testing • Contained LEAD > 3% • Pigment stored in “ Forbidden Area” of factory • Mistakenly used by operator
Slide77CAR Example Root Cause Reporting: • Failed Item: Red pigment • Content: 3% Lead • Reason for Usage: Operator used wrong pigment in “Forbidden Area” • Confirm Problem: XRF-gun testing and 3 rd party lab testing to verify
Slide88CAR Example Action – Short Term: • No customer recall; problem found in production • Quarantine problem pigment, materials and finished shoes in factory • Remade replacement using correct pigment • XRF-Gun testing per shipment for further delivery
Slide99CAR Example Action – Long Term: • Remove problem items from factory • Eliminate “Forbidden Area” to avoid contamination • Improve process control on manufacturing, recording and tracking • Internal training to operators
