Understanding the types of nonconformities (NCs) is essential for maintaining effective management systems and achieving continuous improvement! Each nonconformity has specific characteristics, requiring different approaches for resolution.
Failing to consider the type of NC can lead to several problems. The first is the difficulty in correctly prioritizing actions, as the analysis itself does not take into account the nature of the nonconformities. Additionally, identifying the root cause and developing an action plan—whether immediate or corrective—becomes more challenging.
These issues can result in generic and ineffective responses, leading to a loss of action traceability and organizational learning. This significantly increases the risk of recurrence and causes substantial financial losses for companies.
Therefore, correctly classifying nonconformities is crucial for implementing effective corrective actions, preventing recurrence, and even strengthening corporate culture! In today’s content, we will explore the different types of nonconformities and how to address them.
What Are Nonconformities?
Before we continue, let’s review the basics. Nonconformities are events that indicate a failure to meet requirements, whether related to internal or external stakeholders.
This noncompliance is generally linked to the management system in place. For example, it may compromise the quality of processes or products (ISO 9001), cause environmental issues (ISO 14001), or jeopardize employee safety (ISO 45001), among other examples.
Types of Nonconformities
There are three main types of nonconformities, classified based on the severity or origin of the issue. Let’s examine each one:
Major Nonconformity
A major nonconformity occurs when a requirement is completely disregarded, compromising the effectiveness of both the management system and the company as a whole. For instance, if an ISO 9001-certified company lacks any documented information to support its processes (such as procedures or work instructions), this indicates a systemic failure in the quality management system (Clause 7.5). If left unaddressed, it could result in certification suspension.
Minor Nonconformity
A minor nonconformity, on the other hand, is an isolated or limited noncompliance that does not significantly impact the overall management system or cause substantial harm to the organization. For example, if the same ISO 9001-certified company has all the required documented information, but one employee is using an outdated version of a document—while the correct version is still available in the system—this would be considered a minor nonconformity. The error is specific and can be corrected with a targeted action, without affecting certification or product/service quality.
Routine Nonconformities
These are nonconformities that can be identified at any time by any employee in the company. They can originate internally or externally, such as those reported by customers, suppliers, or auditors.
How to Address Different Types of Nonconformities
Regardless of the source or severity, the treatment of nonconformities must follow a structured process. At a basic level, the resolution process should involve a root cause analysis followed by the development of an action plan to eliminate the identified causes.
During the root cause analysis phase, certain quality tools can help identify the causes more systematically and accurately, improving the overall effectiveness of the process. Let’s explore a few:
- 5 Whys: This simple yet effective methodology helps identify the root cause of a problem by repeatedly asking “Why?” until the true origin of the nonconformity is uncovered.
- Ishikawa Diagram (Fishbone Diagram): This visual tool categorizes possible causes into different factors (Machine, Environment, Methods, People, Materials, and Measurements). By structuring the analysis this way, it becomes easier to pinpoint the most significant contributors to the nonconformity.
- Pareto Diagram (80/20 Rule): This tool is essential for prioritizing which issues to address first. According to Pareto’s Principle, 80% of problems arise from 20% of causes. Stratifying data in this way helps focus corrective actions on the most critical factors.
Using these tools allows organizations to accurately identify root causes. It is essential to involve employees and process operators in this phase, as they have firsthand knowledge of the process and play a key role in both analysis and action plan development.
Developing an Action Plan
After completing the root cause analysis, an action plan should be developed specifically for each type of nonconformity. Generally, companies use tools like 5W2H to plan and guide corrective actions.
For example, if a company identifies that outdated document versions are being used, it should create an action plan to eliminate this nonconformity. Possible actions might include:
- Training and raising awareness among employees
- Collecting and removing all obsolete copies
- Implementing a controlled document system to ensure compliance
The intensity of corrective actions should always be based on the severity, frequency, origin, and other contributing factors. This is why understanding the different types of nonconformities is essential.
Importance of Nonconformities for Businesses
Many organizations and employees perceive nonconformities as negative occurrences. Some employees even hesitate to report them out of fear of consequences.
However, nonconformities are a normal part of any company’s daily operations and must be addressed with seriousness and professionalism. By identifying and properly resolving them, organizations can transform problems into opportunities for improvement, strengthening their management systems and ensuring the quality of products and services.
An effective nonconformity management process contributes to:
- Continuous process improvement
- Prevention of recurrence
- Cost reduction and minimization of rework
- Compliance with standards and regulations
By reporting and correcting nonconformities, companies turn challenges into improvements, ensuring a more efficient management system and a more prosperous and sustainable business.
