#!/usr/bin/env python3
"""Review a corrective action (CAPA) plan against ISO 9001 10.2 and the action-strength hierarchy.
CAPA JSON keys: capa_id, source, problem, correction, root_causes (list of {id, cause, verified, evidence}),
actions (list of {action, type corrective/preventive/correction, cause_id, owner, due}),
effectiveness ({criteria, method, due}), similar_check, updates (FMEA, control plan, procedures, risks)
Checks:
CP001 high no root cause, or the root cause is a symptom or blames a person ('operator error', 'not trained')
CP002 high no corrective action that changes the system: only correction (sort, rework, scrap, replace)
CP003 high no measurable effectiveness criteria, method and due date
CP004 medium weak actions only (retrain, remind, warn, re-brief): add error-proofing or a design/process change
CP005 medium action without owner or due date
CP006 medium root cause with no action, or action linked to no root cause
CP007 medium root cause not verified (switched on/off, reproduced, or data-confirmed)
CP008 low no check for similar nonconformities elsewhere (10.2.1 b 3)
CP009 low no update to risks, FMEA, control plan or documents (10.2.1 e, f)
Action strength (highest first): eliminate > error-proof > automate/detect > standardise > train > remind.
Usage:
python capa_check.py capa.json
Exit codes: 0 no high findings, 1 high findings, 2 read or JSON error.
"""
import argparse
import json
import re
import sys
BLAME = re.compile(r"\b(operator|human|worker|inspector)\s+(error|mistake|fault)|\bnot (properly )?trained|\bcareless|\black of (attention|care|training|awareness)|\bdid not follow|\bforgot\b|\bmistake\b|\bnegligen", re.I)
SYMPTOM = re.compile(r"^\s*(part|parts|dimension|bore|hole)\b.*\b(out of (spec|tolerance)|oversize|undersize|wrong)\b", re.I)
CORRECTION = re.compile(r"\b(sort(ed)?|rework(ed)?|scrap(ped)?|replace(d)?|re-?inspect(ed)?|repaired|returned|credited|segregat)", re.I)
STRENGTH = [ # (rank, label, pattern)
(5, "eliminate", r"\b(redesign|eliminat|remove the (step|need)|change (the )?(design|material|supplier))"),
(4, "error-proof", r"\b(poka[- ]?yoke|error[- ]?proof|mistake[- ]?proof|fixture|interlock|sensor|go/?no-?go|physical stop|keyed)"),
(3, "automate / detect", r"\b(automat|vision|in-?process (gauge|measurement)|100% (check|inspection)|alarm|spc|control chart|tool life (counter|monitor))"),
(2, "standardise", r"\b(procedure|work instruction|wi-|standard work|checklist|control plan|setup sheet|update (the )?(sop|instruction))"),
(1, "train", r"\b(train|retrain|coach|re-?brief|educat)"),
(0, "remind", r"\b(remind|warn|toolbox talk|memo|be (more )?careful|awareness|email)"),
]
def strength(text):
for rank, label, pat in STRENGTH:
if re.search(pat, text, re.I):
return rank, label
return 2, "other"
def check(c):
f = []
causes = c.get("root_causes") or []
if isinstance(causes, str):
causes = [{"id": "RC1", "cause": causes}]
actions = c.get("actions") or []
if not causes:
f.append(("CP001", "high", "no root cause stated"))
for rc in causes:
txt = str(rc.get("cause", ""))
if BLAME.search(txt):
f.append(("CP001", "high", f"{rc.get('id', '')} '{txt[:60]}' blames a person: ask why the process allowed it"))
elif SYMPTOM.search(txt):
f.append(("CP001", "high", f"{rc.get('id', '')} '{txt[:60]}' restates the symptom, not its cause"))
if not rc.get("verified"):
f.append(("CP007", "medium", f"{rc.get('id', '')} not verified: reproduce it, switch it on/off, or confirm with data"))
real = [x for x in actions if str(x.get("type", "corrective")).lower() != "correction" and not
(CORRECTION.search(str(x.get("action", ""))) and strength(str(x.get("action", "")))[0] <= 2 and
not re.search(r"procedure|instruction|fixture|design|process", str(x.get("action", "")), re.I))]
if not real:
f.append(("CP002", "high", "only corrections (sort/rework/scrap/replace): add actions that remove the cause"))
ranks = [(strength(str(x.get("action", ""))), x) for x in real]
best = max((r[0][0] for r in ranks), default=-1)
if real and best <= 1:
f.append(("CP004", "medium", "strongest action is training/reminder: add error-proofing, automation or a design change"))
for (rank, label), x in ranks:
if not (x.get("owner") and x.get("due")):
f.append(("CP005", "medium", f"'{str(x.get('action'))[:50]}' has no owner or due date"))
ids = {str(rc.get("id")) for rc in causes if rc.get("id")}
linked = {str(x.get("cause_id")) for x in real if x.get("cause_id")}
for i in sorted(ids - linked):
f.append(("CP006", "medium", f"root cause {i} has no corrective action"))
for x in real:
if x.get("cause_id") and str(x["cause_id"]) not in ids:
f.append(("CP006", "medium", f"action '{str(x.get('action'))[:40]}' points to unknown cause {x['cause_id']}"))
eff = c.get("effectiveness") or {}
if not (eff.get("criteria") and re.search(r"\d", str(eff.get("criteria"))) and eff.get("method") and eff.get("due")):
f.append(("CP003", "high", "effectiveness check needs a measurable criterion, a method and a date"))
if not c.get("similar_check"):
f.append(("CP008", "low", "record whether similar products, machines or sites have the same cause"))
if not c.get("updates"):
f.append(("CP009", "low", "update PFMEA, control plan, procedures or the risk register as needed"))
return f, ranks
def main():
ap = argparse.ArgumentParser(description=__doc__, formatter_class=argparse.RawDescriptionHelpFormatter)
ap.add_argument("capa", help="CAPA JSON, or - for stdin")
a = ap.parse_args()
try:
c = json.load(sys.stdin if a.capa == "-" else open(a.capa, encoding="utf-8"))
if not isinstance(c, dict):
raise ValueError("CAPA JSON must be an object")
except (OSError, ValueError) as e:
print(f"error: {e}", file=sys.stderr)
return 2
f, ranks = check(c)
print(f"{c.get('capa_id', '(no id)')}: {c.get('problem', '')[:80]}")
if ranks:
print("Action strength:")
for (rank, label), x in sorted(ranks, key=lambda r: -r[0][0]):
print(f" [{rank}] {label:<18}{str(x.get('action'))[:70]}")
print()
for code, sev, msg in f:
print(f"{code} [{sev}] {msg}")
print(f"\n{len(f)} issue(s)" if f else "Plan meets 10.2 and uses strong actions.")
return 1 if any(x[1] == "high" for x in f) else 0
if __name__ == "__main__":
sys.exit(main())
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