KISF-002A (Version 01)

ABNORNALITY CONTROL Document No.: KISP024 Version No. 02

PROCEDURE Originated By: ISO Office Page 1 of 3

1. Purpose:
To define a standard flow of information, accountability and responsibility to facilitate quick
and proper response and disposition to abnormalities.
2. Definition:
Abnormality is the presence of any condition different from usual or acceptable condition.
3. General Requirements:
Top Management with each Department Manager is responsible for increasing team
members’ awareness and sensitivity to abnormalities and acting in according to procedures
and instructions by:
3.1. Making them accustomed to a work environment including layout and infrastructures that
are well maintained where abnormal conditions (appearance, sound, vibration, smell,
etc.) will be easily noticed.
3.2. Identifying abnormal situations that may arise from different processes and documenting
action plans using any of the following media or equivalent
- Procedures and Work Standards
- Posters and Visual Aids
3.3. Providing them with simple and clear-cut instructions to observe and follow during work
and significant abnormalities and to extent possible, providing them with a written
contingency action plan in case of abnormal situations.
In case no contingency action plan or work standard is available on how to deal
with an abnormal incident, a temporary instruction must be issued in the form of Work
Instruction Notice, where the absence of which could lead to NG product leak out or
imminent safety/environmental hazard [2].
3.4. Setting visual controls, limiting standards or criteria to judge by themselves whether or not
a situation is normal or abnormal.
Examples:
- Control charts
- Internal product specifications where none has been provided by the customer or
where initial specifications are impossible to obtain using approved process
conditions.
- Gage markers (green for w/in standard and red for outside tolerance)
- Labels to indicate normal position of levers (normally closed or normally open)
- I-marks, Jigs and Poka-Yoke devices
- Samples for comparison
3.5. Setting visual controls, limiting standards or criteria to judge by themselves whether or not
a situation is normal or abnormal.
3.6. Establishing instructions on how to identify scope of affected products/items for purposes
of carrying out immediate recall and/or retroactive action. [2]
KISF-002A (Version 01)

ABNORNALITY CONTROL Document No.: KISP024 Version No. 02

PROCEDURE Originated By: ISO Office Page 2 of 3

4. Internal Communication and Responsibility Chart

Person to identify disposition method or decides on what to do.

NOTE: Approval shall be required if so indicated in the Disposition Approval
Chart
Person to take action to correct abnormality
Evaluation point
Flow of reporting
Flow of instruction
Rank A Abnormality that cannot be immediately corrected nor contained (example:
outflow of NG parts to customer, delay in operations or delivery, legislative
repercussions, nonconformance to strict customer instructions, unplanned
use of resources).
Rank B Abnormality occurs for the 1st time or course of action has yet to be
established. For inherent or recurrent abnormality to be ranked as B, effect
of such abnormality is of bigger magnitude than expected.
Rank C Abnormality or source of abnormality is understood, easily corrected or
located. Abnormality may be inherent or recurrent that course of action has
already been defined or established.

STOP
PERSON FINDS
THE
ABNORMALITY

CALL

W/ LEADER ASV/SV MANAGER TOP

INSTRUCTION DECIDES ON DECIDES ON DECIDES ON MANAGEMENT
WHAT TO DO WHAT TO DO WHAT TO DO DECIDES ON
WHAT TO DO

WAIT NO NO NO

Rank C Rank B Rank A

YES YES YES

ACTION

PERSON IDENTIFIED TO CARRY OUT INSTUCTIONTAKES ACTION

KISF-002A (Version 01)

ABNORNALITY CONTROL Document No.: KISP024 Version No. 02

PROCEDURE Originated By: ISO Office Page 3 of 3

5. Disposition Approval Chart

APPROVAL

CHOICE/
QUESTION

NO
PRODUCT
QUALITY ?

YES

INSPECTION/ NO SPECIAL NO DISPOSAL OF

REWORK/ ACCEPTANCE PARTS/
SORTING ? MATLS?

YES YES YES

ALL MANAGERS +
QA MANAGER NO NEED TOP MANAGEMENT
CUSTOMER
INFO?

YES
QA MANAGER +
CUSTOMER

NO/
MINIMAL
DEPARTMENT COST?
MANAGER

YES

NO CIVIL/ ELECL/ NO MANPOWER/

MECHL /ENVL LABOR
CHANGE

YES YES

SAFETY & POLLUTION

CONTROL OFFICER

HRAD MANAGER

TOP MANAGEMENT