Supplier Overview of Johnson & Johnson MD&D Supplier Quality Standard Operating Procedures (SOPs)

Transcription

1 Supplier Overview of Johnson & Johnson MD&D Supplier Quality Standard Operating Procedures (SOPs) Supplier Responsibilities for Failure Investigations and Problem Solving

2 Purpose of this SOP Establishes the process for failure investigations and problem solving activities conducted by suppliers Applies to CAPAs, nonconformances, SCARs (Supplier Corrective Action Requests), etc. A Supplier Failure Investigation and Problem Solving Template is provided 2

3 Scope of Supplier Failure Investigation SOP Begins when a supplier has been notified of an issue (nonconformance, CAPA, etc.) Ends when the supplier has completed all activities agreed to with J&J MD&D to execute and document the failure investigation and problem solving associated with an issue Links supplier Failure Investigation (FI) and Problem Solving (PS) activities with the overall J&J MD&D expectations for Failure Investigation and Problem Solving Overall MD&D FI/PS Expectations MD&D Supplier FI/PS SOP Supplier FI/PS Activities 3

4 Key Definitions Correction - Action to eliminate a detected nonconformity. A repair, modification, adjustment, relabeling, destruction or inspection of a product or process. Corrective Action - Action to eliminate or reduce the cause or effect of a detected nonconformity or other undesirable situation, in order to prevent recurrence. Preventive Action - Action to eliminate or reduce the cause or effect of potential nonconformity, defect or other undesirable situation, in order to prevent occurrence. 4

5 Responsibilities Suppliers are responsible for conducting and documenting the supplier failure investigation and problem solving activities for supplier related issues Supplier are also responsible for submitting documentation related to the failure investigation as requested by the J&J MD&D Operating Company that requested the failure investigation 5

6 Key Requirements Suppliers to expected to use the specified response format when a failure investigation is requested The SOP does allows flexibility for a supplier s format The template provided with the SOP can be used as the form, or at a minimum can act as a guide for the failure investigation process The J&J MD&D form has definitions and walks the user through the process 6

7 The Supplier Failure Investigation and Problem Solving Process Includes the Following Steps: Problem Statement / Supplier notification Bounding and containment Preliminary cause analysis (rationale for bounding) Corrections Root cause Plan corrective/preventive actions & effectiveness monitoring Execute the plan and document actions taken Monitor effectiveness 7

8 Problem Statement & Bounding/Containment The process starts with a good Problem Statement Clearly and factually describe the current condition as compared to the should-be condition Measureable (how often, how much, when, where) and fact-based Supplier to conduct bounding and containment Locating and segregating suspect/nonconforming material at all locations (supplier, sub-tiers, alternate sites, etc.) Broad based approach identifying product that may be impacted Should be based on Preliminary Cause Analysis (PCA provides a rationale for bounding) 8

9 Preliminary Cause Analysis Extent of bounding should be based on Preliminary Cause Analysis (PCA) - provides rationale for bounding PCA is essentially the start of root cause identification Output of PCA is an understanding of potential causes, which can be used to establish bounding Tools such as 5-Why should be used 9

10 Corrections Corrections: Documented action taken to eliminate and/or rework, repair, or a contain a detected nonconformity(s) and to document the final product disposition Root cause not required for correction, rather it focuses on ensuring that the defects in question are properly controlled Any new controls/rework should be evaluated for the need to be verified or validated Corrections can have unintended consequences (e.g. removing burrs can result in foreign matter/contamination) The SOP and template are intended to aid suppliers in understanding the differences between Correction and Corrective Action 10

11 Root Cause Identification Continuation of any Preliminary Cause Analysis activities Document the root cause(s) that if corrected prevents reoccurrence of the same event. If root cause not confirmed then identify probable cause. Provide a rationale for root cause selection Whenever possible, this can be accomplished by confirming the selected root cause turns the issue on/off Identify and attach tools used, such as 5-Why In most cases training or human error is not the root cause After root cause identification, ensure bounding is still appropriate Identify any controls that were not effective 11

12 Planning Corrective and Preventive Actions Establish planned corrective and/or preventive actions Who, what, when Corrective actions prevent recurrences by eliminating causes. Corrective Action is designed to prevent the recurrence of nonconformities/issues. While corrective actions prevent recurrence, preventive actions prevent occurrence (to prevent the occurrence of situations that do not yet exist) Don t just think of the single part, product, process or plant Where applicable, plan to update FMEAs and control plans Training should typically not be the only corrective action Document an effectiveness monitoring plan Additional CA/PA planning details are provided in the SOP 12

13 Execute and Document Actions Taken Carry out and document actions per established timing Notify J&J MD&D of any changes to the plan Verify/validate as appropriate Provide summary of investigation/activities and evidence Monitor/document effectiveness as defined in the plan If not effective, continue with the Failure Investigation process 13

14 Supplier Failure Investigation and Problem Solving Template The Supplier Failure Investigation and Problem Solving Template walks the user through the failure investigation process 14

15 Supplier Failure Investigation and Problem Solving Template The template includes definitions for key terms and can be used as a process guide even if an alternate form is being used 15

16 Supplier Failure Investigation and Problem Solving Template Planned actions and problem solving progress can be documented in the Supplier Failure Investigation Template 16