| Control | How |
|---|---|
| ERP block | Supplier master status drives PO creation: disqualified / pending cannot receive POs; scope codes restrict commodities |
| PO requirements | Drawing and revision, specification, quality clauses (certificates, right of access, flow-down, notification of changes, counterfeit prevention), approved special-process sources |
| Receiving check | Receiving verifies the supplier and scope against the ASL before acceptance |
| Monthly audit | asl_audit.py --pos on last month's POs: any AL001 / AL002 is a nonconformity against 8.4 |
| Change notification | Suppliers must notify changes of site, process, sub-supplier, material, ownership; trigger re-approval / PPAP |
| Certificate watch | Expiry dates tracked; request renewals 60 days ahead; suspended certificates move the supplier to conditional |
Handling an off-list purchase
- Quarantine material received from the off-list supplier.
- Raise an NCR against the purchasing process (internal), not against the supplier.
- Decide: approve the supplier through the normal process, or return / scrap.
- Correct the system gap (ERP block missing, emergency buy procedure unclear).
Emergency purchases
Allow them only through a documented route: quality approval before the PO, enhanced receiving inspection, retrospective evaluation within a set time. Record every emergency buy and review the count at management review.
8d-problem-solving-report-writer
Write and review 8D problem-solving reports for customer complaints and serious nonconformities (automotive and aerospace practice: Ford Global 8D, VDA, GM, Stellantis formats): D0 emergency response, D1 cross-functional team and champion, D2 problem description with 5W2H and is / is-not and no cause in the statement, D3 interim containment within 24 hours with verification and clean point, D4 verified occurrence and escape (non-detection) root causes plus systemic cause, D5 permanent corrective actions for each cause verified before implementation, D6 implementation, validation with production data and removal of containment, D7 PFMEA, control plan and read-across to similar products, D8 closure and recognition. Checks an 8D discipline by discipline for missing content, human-error root causes, missing escape cause or action, late containment and dates out of order.
acceptance-sampling-plan-selector
Select and evaluate acceptance sampling plans for incoming, in-process and final inspection: ANSI/ASQ Z1.4 / ISO 2859-1 single sampling under normal inspection (code letter from lot size and inspection level I, II, III, S-1 to S-4; sample size, Ac and Re from AQL, following the table's arrows to the correct plan; 100% when n reaches the lot size; AQLs above 10 per 100 units), operating characteristic curves (Pa at any quality, producer's quality level, indifference point, LTPD, AOQ and AOQL, binomial or hypergeometric), plans designed from producer and consumer risk, and c = 0 zero-acceptance plans. Covers AQL choice by defect class, switching rules between normal, tightened and reduced inspection, when sampling is not appropriate, and random sampling.
apqp-phase-planner
Plan and track Advanced Product Quality Planning (AIAG APQP 3rd edition, IATF 16949) for a new or changed automotive part: back-schedule the five phases (plan and define, product design, process design, product and process validation, launch and feedback) from the start-of-production date by program complexity, with overlap, PPAP lead and safe-launch period; list the deliverables and gate for each phase (DFMEA, DVP&R, feasibility, process flow, PFMEA, control plans, MSA, Ppk, run at rate, PPAP, safe launch, lessons learned); adjust for build-to-print suppliers; flag compressed timelines and late or untracked deliverables against a status list. Covers gate reviews, red/yellow/green status reporting, run at rate and safe-launch exit criteria.
as9100-gap-analyzer
Run an AS9100D / EN 9100:2018 gap analysis for aviation, space and defence suppliers on the requirements added to ISO 9001: on-time delivery and conformity focus, management representative, ethics and human-factors awareness, operational planning and operational risk management, configuration management, product safety, counterfeit-part prevention, special requirements, critical items and key characteristics, external provider register and flow-down, FOD prevention, tooling and NC program control, special process validation, first article inspection (AS9102), traceability, in-service data and nonconforming product control. Generates and scores a worksheet, grades missing core controls as major, and checks invalid n/a claims. Covers AS9101/AS9104, OASIS, AS9102 FAI forms, counterfeit standards (AS5553, AS6174, AS6081), NADCAP and the planned IA9100 transition.
audit-report-writer
Write internal, supplier and pre-certification audit reports with the content ISO 19011:2018 6.5 expects: audit objectives, scope, criteria with revisions, dates, team and auditees, method and sampling statement, specific strengths, findings table and three-part finding details (requirement, evidence, statement), conclusion on the degree of fulfilment of criteria, diverging opinions, follow-up deadlines and distribution. Builds a Markdown report from a JSON audit record, generates the conclusion from the findings (major / minor / none) and flags reports missing required content or findings without clause or evidence. Covers conclusion wording, closing meetings, response expectations and verifying corrective actions.
capa-effectiveness-checker
Verify whether a corrective action actually worked (ISO 9001 10.2.1 d, IATF 16949, 8D D6) with statistics instead of 'no complaints so far': before/after defect-rate comparison with an exact conditional binomial test for Poisson counts and a minimum practical reduction, zero-defect demonstration size (n = ln(1-C)/ln(1-p), rule of three) with progress so far, and exact Clopper-Pearson upper bounds on the post-action defect rate. Returns effective, not yet demonstrated (with the units still needed) or not effective. Covers setting effectiveness criteria when the CAPA is opened, choosing the window by problem frequency, leading indicators for rare failures (Cpk, SPC stability, error-proofing checks, LPA), and traps such as volume changes, detection changes and containment masking.