Tell it what is wrong and where the material could be. It builds a checklist you can tick through or print and take to the floor, with a count line at every location and a sign off at the end.
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What the checklist covers
| Part | What it asks |
|---|---|
| Stop it moving | Identify the lot, set the suspect window, keep a sample of the defect, set up quarantine and red tag. |
| Find it | Steps for each place the material could be, with a count line for each one. If you are not sure how far it goes, it covers every location, the supplier included. |
| Does the count add up | Compare what you found with what was received or made in the suspect window. If the numbers do not match, keep looking. |
| Sort and decide | Sort method, who does it, who releases good parts, and a count of good, scrap and rework. |
| Tell people | Production, purchasing, the customer when it shipped, and anyone who handles the part. |
| Close it out | Release only what was signed off, and ask for corrective action in writing. |
Worked example
Receiving finds the hole position out of tolerance on lot 4471 of a steel bracket. Material is on the dock, in stores and on a line, and some finished goods are already built from it. Tick those four places and the builder gives the stop steps, one set of steps for each place with a count line, then the sort, tell and close out steps.
It leaves out the customer steps because nothing shipped. Tick "Shipped to the customer" and the customer notice and replacement stock steps appear.
Why this order
Containment fails when someone finds one box and stops. The suspect window tells you where to look, and the count at each location tells you whether you found it all. Containment protects the customer while you work out the cause. It does not fix anything. Read the difference in containment vs correction vs root cause.
This is a working checklist, not a replacement for your own procedure. If your customer or your quality system sets a notice time or a required method, follow that first.