Supplier Scar

Supplier Corrective Action Request (SCAR)

When to use

Use this skill when:

• A supplier NCR requires a formal corrective action (beyond simple return/replacement)
• A supplier has delivered the same non-conformance twice or more
• A non-conformance has caused a production line stoppage, customer complaint, or field failure
• A supplier's quality performance score falls below the defined threshold
• An OEM customer issues a concern that is traced to a sub-supplier
• Preparing a SCAR, evaluating a supplier's 8D response, or conducting an effectiveness review

Prerequisites

• Non-conformance documented (NCR or equivalent) with: part number, description, quantity, measured evidence
• Supplier code, contact name, and corrective action coordinator identified
• SCAR response timeline agreed (typically 24h for D3, 30 days for full 8D)
• Historical data: previous SCARs, PPM trend, quality score for this supplier

Workflow

Step 1 — Escalation criteria: when does an NCR become a SCAR?

Issue a SCAR when any of the following conditions are met:

Do NOT issue a SCAR for every NCR — use NCR + return for minor first-occurrence issues and reserve SCAR for systemic or high-risk situations.

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Step 2 — Write the SCAR

The SCAR document must contain:

Header:

• SCAR number (unique, traceable)
• Date issued
• Supplier name, supplier code, contact person
• Issued by (supplier quality engineer name)

Non-conformance description:

• Part number and revision
• Delivery reference (PO number, lot number, delivery note)
• Quantity delivered / quantity non-conforming / % affected
• Defect description in objective-evidence language (measured values vs. specification — not opinions)
• Customer impact (if applicable): production stop, customer complaint, field return
• Reference to the NCR (attach or link)

Response requirements: Specify exactly what the supplier must provide and by when:

Always require TWO root causes: why the defect was produced (occurrence) AND why it was not detected (escape).

Containment verification: State that the supplier must confirm:

• All suspect stock at their facility has been identified and quarantined
• All stock in transit has been recalled or placed on hold
• All stock at your facility has been segregated (include quantity)
• A containment verification plan is in place before any further shipments are accepted

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Step 3 — Evaluate the supplier's 8D response

Use the 8D Evaluator methodology (skill: 8d-problem-solving) to review the supplier's response. Focus on the most common SCAR-specific failures:

D3 — Containment:

• Is the containment in PAST TENSE? (If it says "we will inspect going forward" — reject)
• Does it cover all locations (supplier, transit, your facility, customer)?
• Is there a verification result (quantity sorted, quantity rejected, quantity cleared)?

D4 — Root cause:

• Are BOTH causes identified: occurrence (why produced) AND escape (why not caught)?
• Is the root cause supported by evidence, or is it opinion?
• Reject: "human error", "operator oversight", "customer changed specs" — always ask why it was possible
• Verify: if the supplier claims "operator error", ask why the error was not detected by the control plan

D5 — Permanent corrective action:

• Does the PCA directly address the confirmed root cause?
• Is "retrain the operator" the only action? If so, reject — training is not a systemic fix
• Is there a poka-yoke or process change that makes the defect impossible or immediately detectable?

D7 — Systemic prevention:

• Has the PFMEA been updated to reflect the failure mode and new controls?
• Has the Action Priority (AP) been revised in the PFMEA after verified corrective action? The revised AP must be lower than the original or documented with justification — AP revision is only valid after D6 effectiveness is confirmed, not at planning stage.
• Has the Control Plan been updated?
• Have Work Instructions been updated?
• Has horizontal deployment been considered (same process at other lines/plants)?

D6 — Verification:

• Is there production data showing the PCA is effective?
• What quantity was run? Over what period?
• What is the measured improvement (before/after comparison)?

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Step 4 — Issue a SCAR response rejection

If the supplier's 8D response does not meet the gate criteria, reject it formally:

Rejection notice must specify:

• Which discipline(s) failed and why (specific, not generic)
• What is required in the revised response
• Revised deadline for resubmission

Do not accept a response that:

• Has no evidence of D3 completion (only a plan)
• States "human error" as the final root cause without systemic analysis
• Lists only training as the PCA
• Has no PFMEA or CP update in D7
• Shows no production data in D6

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