Use a corrective-action request when an inspection, test, delivery, or field result shows a problem that can recur. The objective is not a longer apology; it is evidence that affected product is controlled and the process cause has changed.
Problem statement
Record the requirement, actual result, product and lot, quantity affected, discovery point, date, and objective evidence. Avoid labels such as “poor quality” without measurements or photographs.
Immediate containment
- Stop shipment or production where needed.
- Identify and segregate suspected material and finished goods.
- Determine affected lots, customers, locations, and dates.
- Define sorting, rework, replacement, or disposal.
- Verify that containment is effective.
Root cause
Separate the occurrence cause—why the defect happened—from the escape cause—why existing controls failed to detect or stop it. Evidence may include process data, material records, interviews, test results, and reproduction trials.
“Operator error” is incomplete unless the analysis explains why the process allowed the error and why it was not detected.
Permanent action
State the specific change to material, equipment, tooling, method, parameter, error-proofing, work instruction, inspection, training, or supplier control. Assign an owner and completion date. Update specifications and control plans where necessary.
Effectiveness verification
Define how many future lots, units, cycles, or weeks will be reviewed; what result constitutes success; and who closes the action. Retain evidence of the review.
Extend the action to similar products or processes when the same cause could exist elsewhere. A passed reinspection proves the corrected lot met the sample decision rule; it does not by itself prove that recurrence was prevented.