How to Issue and Close an NCR for Nonconforming Tower Internals

A nonconformance does not automatically mean the entire order must be rejected.

It means the supplied product or manufacturing activity differs from an approved requirement.

The purpose of an NCR—Nonconformance Report—is to control that difference until a formal disposition is reached.

What Should Trigger an NCR?

Examples may include:

• wrong material;
• incorrect dimension;
• missing component;
• unacceptable weld;
• wrong wire diameter;
• damaged packing;
• failed test;
• incorrect hole pattern;
• undocumented design change.

The issue should be tied to a defined requirement.

Describe the Actual Condition

A strong NCR states exactly what was found.

Weak:

“Distributor dimension wrong.”

Strong:

“Outlet flange centerline measured EL +4310 mm; approved Drawing D-101-R2 requires EL +4350 mm.”

The second statement provides a measurable technical basis.

Reference the Requirement

Every NCR should identify the controlling:

• drawing;
• specification;
• PO clause;
• test requirement.

This prevents debates over what the correct condition was supposed to be.

Contain the Nonconforming Item

Before disposition, the supplier should prevent accidental use or shipment.

This may require:

• tagging;
• segregation;
• production hold;
• document flag.

The degree of containment depends on the product.

Determine the Extent

If one piece is wrong, ask whether the problem affects:

• one item;
• one lot;
• one production run;
• the whole shipment.

For example, one incorrect PP packing sample may indicate:

a single damaged mold cavity or a complete wrong resin batch.

Supplier Proposed Disposition

The supplier may propose:

• rework;
• repair;
• replace;
• use-as-is;
• scrap.

The purchaser should review the proposal where project approval is required.

Corrective Action Is Not Always the Same as Disposition

Disposition solves the specific nonconforming item.

Corrective action addresses why it happened and how recurrence will be prevented.

For minor isolated issues, formal root-cause analysis may not always be necessary.

For repeated or serious problems, it can be valuable.

Verify the Rework

If the item is reworked, it should be re-inspected against the approved requirement.

An NCR cannot be closed simply because someone says:

“fixed.”

There should be evidence.

Update Records

If the final accepted configuration differs from the original drawing, relevant documentation may need updating.

This is especially important for:

use-as-is or approved deviation cases.

Close the NCR Formally

Final closure should record:

• disposition;
• approval;
• verification;
• date;
• supporting documents.

An open NCR should not disappear merely because shipment is approaching.

Engineering Takeaway

An NCR provides a controlled path from identified nonconformance to documented disposition and verification.

It prevents informal workshop decisions from becoming hidden project changes.