The same quality issue keeps returning
Track corrective action and confirm the cause was removed.
01 · What is usually happening?
A complaint arrives, someone fixes the batch, and the file is closed. Three months later the same defect returns because the cause was never found or the fix was never made permanent.
The business keeps paying to fix the symptom.
The question people usually ask“Why is it back?”
The more useful question“What was the real cause, what changed, and how do we know it stayed fixed?”
02 · Common causes
- 01The first fix addresses the part, not the cause
- 02No root cause is written down
- 03The change is made verbally and not in the instructions
- 04Nobody checks after a month that the fix held
- 05Different shifts follow different methods
- 06Past issues cannot be searched
03 · What to check now0 of 6 checked
04 · What good looks like
- 01Each issue records a cause and a change.
- 02The change is written into the standard.
- 03A check is made after a set time.
- 04All shifts use the same method.
- 05Past issues can be found by part and defect.
05 · Where this connects
This rarely stays in one department
What it can lead to: The same defect is paid for repeatedly and customers lose patience.
Start from a problem
Work flows left to right, top to bottomKEYMost important for manufacturing
These support every part of the business
Problem
The same quality issue keeps returning
Usually connected to
How it spreads
- Quality
What it can lead to: The same defect is paid for repeatedly and customers lose patience.
lamplamp could open a corrective action from a repeat defect.
06 · Related processesQuality issue to closure
07 · Useful toolsTemplateQuality Issue Log
Related guidesWhat a production supervisor needs at shift handover
08 · lamp
lamp could keep this moving
lamp is not available yet. These are things it is being built to do.
- lamp could open a corrective action from a repeat defect.
- lamp could remind the owner to check that the fix held.
- lamp could show past issues for the same part and defect.
- lamp could list actions still open past their date.
Does your business handle this differently?Tell us what we have missed: a cause, a check, or a better way of handling it.
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