Non-conformances
Every non-conformance carries a disposition, a cause and the rework it caused in hours and dollars. The hours here are the same rework bookings that sit outside the quoted hours on the job — which is what makes the cost of quality a real number rather than an estimate. Drag a card to move it along.
Open
4
14 raised this year
Rework hours
62.5 h
Indirect — never charged to a quote
Cost of rework
$3,890
Labour at the shop cost rate
Supplier caused
3
21% of the register
Open 2 $680
Awaiting disposition 1 $244
Verification 1 —
Closed 10 $2,966
NCR-2026-028 Two tube-to-tubesheet joints leaking at first hydro NCR-2026-027 Baffle spacing 12mm out at positions 4 and 5 NCR-2026-025 Undercut on nozzle N2 saddle weld NCR-2026-024 Customer witness unavailable at nominated hold point NCR-2026-023 P&ID revision issued after fabrication release NCR-2026-022 Tubesheet drilling — 4 holes 0.3mm oversize NCR-2026-021 Galvanising — two receivers returned for re-dip NCR-2026-020 Hardness survey above limit on PWHT coupon NCR-2026-019 Dished ends out of form tolerance on delivery NCR-2026-018 Incorrect consumable used on two economiser headers
Where it is coming from
By cause, ranked on what it cost
| Cause | Count | Hours | Cost | |
|---|---|---|---|---|
| Heat treatment | 1 | 14.0 | $865 | |
| Welding — shielding gas | 1 | 11.0 | $680 | |
| Welding — wrong consumable | 1 | 9.0 | $556 | |
| Workmanship — wrong cut list | 1 | 8.0 | $494 | |
| Tube expanding | 1 | 6.0 | $371 | |
| Machining | 1 | 5.0 | $309 | |
| Welding — technique | 1 | 4.0 | $247 | |
| Supplier — material out of spec | 2 | 3.5 | $244 | |
| Outside process — coating | 1 | 2.0 | $124 | |
| Fit-up — dimensional | 1 | — | — | |
| Supplier — short delivery | 1 | — | — | |
| Customer — hold point | 1 | — | — | |
| Customer — late change | 1 | — | — |
Supplier material out of spec and welding between them account for most of it. Both feed the supplier
performance report and the welder continuity check.
By source
In-house7
Supplier3
Customer2
Third-party inspection2
Third-party findings are counted separately from in-house ones, because an inspector finding it is a
different problem from finding it yourself.
Register
14 shown | NCR | Raised | Job | Source | Disposition | Rework | Cost | Status |
|---|---|---|---|---|---|---|---|
| NCR-2026-031Porosity in shell longitudinal seam LS-2, 340mm run | 6 Aug 2026DN | JN 174312 | In-house | Repair | 11.0 | $680 | Open |
| NCR-2026-030Tube bundle — 6 tubes outside OD tolerance | 4 Aug 2026MK | JN 174327 | Supplier | Return to supplier | 3.5 | $244 | Awaiting disposition |
| NCR-2026-029Nozzle N4 projection 8mm over drawing | 29 Jul 2026DN | JN 174298 | Third-party inspection | Use as is | — | — | Verification |
| NCR-2026-028Two tube-to-tubesheet joints leaking at first hydro | 24 Jul 2026HS | JN 174331 | In-house | Rework | 6.0 | $371 | Closed |
| NCR-2026-027Baffle spacing 12mm out at positions 4 and 5 | 18 Jul 2026RT | JN 174321 | In-house | Rework | 8.0 | $494 | Closed |
| NCR-2026-026Dished end delivered short — 1 of 2 | 15 Jul 2026KB | JN 174338 | Supplier | — | — | — | Open |
| NCR-2026-025Undercut on nozzle N2 saddle weld | 9 Jul 2026AR | JN 174287 | In-house | Repair | 4.0 | $247 | Closed |
| NCR-2026-024Customer witness unavailable at nominated hold point | 30 Jun 2026DN | JN 174276 | Customer | — | — | — | Closed |
| NCR-2026-023P&ID revision issued after fabrication release | 26 Jun 2026SP | JN 174316 | Customer | — | — | — | Closed |
| NCR-2026-022Tubesheet drilling — 4 holes 0.3mm oversize | 19 Jun 2026CC | JN 174312 | In-house | Repair | 5.0 | $309 | Closed |
| NCR-2026-021Galvanising — two receivers returned for re-dip | 11 Jun 2026BM | JN 174305 | In-house | Rework | 2.0 | $124 | Closed |
| NCR-2026-020Hardness survey above limit on PWHT coupon | 28 May 2026DN | JN 174264 | Third-party inspection | Rework | 14.0 | $865 | Closed |
| NCR-2026-019Dished ends out of form tolerance on delivery | 14 May 2026KB | JN 174258 | Supplier | Return to supplier | — | — | Closed |
| NCR-2026-018Incorrect consumable used on two economiser headers | 6 May 2026TS | JN 174283 | In-house | Rework | 9.0 | $556 | Closed |