QP-8.5 Corrective Action

Revision F · Effective 2025-08-04

1 Purpose

This procedure defines how Tallgrass Precision Components contains problems, finds their root cause, and puts in place actions that stop them from recurring, using the Corrective Action Request (CAR), form F-850-01, in 8D format.

2 Scope

Applies to internal problems, customer complaints, escapes and audit findings. Supplier-caused problems are handled with a SCAR (F-740-03) per QP-7.4 and SQM-01; a Tallgrass CAR is also opened when the supplier issue reached a customer.

3 Definitions

• CAR - Corrective Action Request, F-850-01. CARs are numbered CAR-YYYY-nnn in the ERP (for example CAR-2025-014).
• Containment - immediate action to protect the customer and stop further nonconforming output.
• Root cause - the underlying reason the problem occurred and was not detected.
• Effectiveness check - verification, after implementation, that the problem has not recurred.

4 Responsibilities

• Quality Engineer (Tomas Reyes) - owns this procedure, opens CARs, maintains the CAR log, and performs effectiveness checks.
• CAR owner - the manager of the process where the cause lies; leads the 8D team and completes each step on time.
• Quality Manager - approves root cause and action plans, approves CAR closure, and reports CAR status at management review.

5 Procedure

5.1 CAR triggers

A CAR is opened for:

1. three or more NCRs with the same part number and the same cause within 90 days (see QP-7.5);
2. any customer complaint, whether or not product is returned;
3. any escape (nonconforming product shipped to a customer);
4. any major audit finding, whether from an internal audit (see QP-8.2), a customer audit or a registrar audit.

Any employee may also request a CAR through their manager or the Quality Engineer for a problem not listed above.

5.2 Timelines

8D step	Requirement	Due
D1-D2	Team formed; problem described (what, where, when, how many)	When the CAR is opened
D3	Containment in place: hold stock, sort, notify affected areas	Within 24 hours of CAR opening
D4-D5	Root cause identified and verified; action plan approved	Within 10 working days of CAR opening
D6	Corrective actions implemented	Within 30 days of CAR opening
D7	Recurrence prevented: documents, training and similar parts or processes updated	With D6
D8	Effectiveness check completed	90 days after implementation

When a customer specifies a shorter response time, the customer's timeline governs. An extension to D4-D5 or D6 must be approved by the Quality Manager before the due date and recorded on the CAR with the reason.

5.3 Root cause analysis

Root cause is determined with 5-Why and, for problems with several possible causes, a fishbone (Ishikawa) diagram. The analysis must address both why the problem occurred and why it was not detected. "Operator error" is not accepted as a root cause on its own; the team must identify why the process allowed the error. When training is identified as a cause, the training matrix is reviewed per QP-6.2.

5.4 Actions and document changes

Actions that change a procedure, work instruction, CMM program or form are made through a DCR (F-420-01) per QP-4.2, and the DCR number is recorded on the CAR. Actions for CMM programs follow WI-215.

5.5 Effectiveness check

Ninety days after implementation the Quality Engineer reviews NCR, customer and audit data for recurrence. If the problem has not recurred and the actions are still in place, the Quality Manager closes the CAR. If it has recurred, the CAR is reopened at D4 and the root cause is re-examined.

5.6 Tracking and escalation

The Quality Engineer maintains the CAR log on the Quality SharePoint site. Open CARs are reviewed at the monthly quality metrics meeting, and any CAR step more than 5 working days overdue is escalated to the President. CAR counts, overdue CARs and effectiveness results are an input to management review (QM-01).

5.7 Customer CARs

When a customer issues its own corrective action request, the Quality Engineer opens a matching Tallgrass CAR, answers in the customer's format, and records the customer's reference number on F-850-01. The Quality Manager approves every response before it is sent.

6 Records

CARs (F-850-01), supporting analysis and evidence of effectiveness are quality records retained 10 years from creation per QP-4.2.

7 Revision history

Rev	Date	Change	Approved by
D	2020-06-08	Adopted 8D format on F-850-01.	Ruth Okafor
E	2023-01-16	Added repeat-NCR trigger (3 in 90 days).	Ruth Okafor
F	2025-08-04	Containment within 24 hours; effectiveness check set at 90 days after implementation; "operator error" not accepted as sole root cause; escalation of overdue steps to the President.	Ruth Okafor