Packaging Nonconformance Report Template
When a pallet of printed packaging is wrong, the first hour decides how far the problem spreads. This NCR template captures the defect, the quantity, the containment and the disposition in one signed record.
Fill in
Packaging Nonconformance Report Template
Packaging Nonconformance Report
Company: Harbor Packaging Co. NCR number: NCR-2026-0412 Date raised: 2026-10-20 Item: Printed carton 12 ct, SKU 5012345 Lot / job: J-24-1187 / Lot 4410 Quantity affected: 14,500 cartons (3 pallets)
Classification
Defect class: Major Defect type: Colour variation Where found: Final inspection
Description
Brand red measured Delta E 5.2 against signed proof, above the limit of 3. Defect present from sample taken at 14:20 onward.
Containment
Three pallets tagged and moved to quarantine. Retained samples pulled from preceding 2 pallets for sorting.
Disposition
Scrap
Root cause and corrective action
| Item | Detail | Owner | Due date |
|---|---|---|---|
| Root cause | |||
| Corrective action | |||
| Preventive action | |||
| Effectiveness check |
Approvals
Starting point only. Align classes and disposition rules with your quality system and customer agreements. Concessions to use nonconforming product normally need written customer approval.
Link NCRs to ERP quality holds
Optional: a short review of how to block affected lots in your ERP when an NCR is raised.
Optional. The tool and every export work without this. No spam.
How to use the template
Fill in the job and lot so the defect can be traced, then state the quantity affected as best known. Classify the defect, describe what was measured versus what was required, and record the containment you took immediately. Export to PDF or Word, route for approval, and complete root cause and corrective action in the table once the investigation finishes.
Good descriptions and containment
A useful description includes the requirement, the measured value and when the defect started. That lets quality bracket the affected lots by checking retained samples. Containment should cover finished stock, work in progress and anything already shipped. Record where the quarantined pallets sit.
- State the requirement and the measurement, not just 'looks wrong'
- Check retained samples before and after the defect
- Block affected lots in the ERP so they cannot ship
- Notify the customer promptly when product has shipped
Common mistakes
Frequent errors include closing the NCR at disposition without a root cause, scrapping product without recording quantity, and failing to check lots produced before the detected failure. Another is using the NCR as a blame record. Keep the focus on the process failure and the check that should have caught it.
Frequently Asked Questions
What is the difference between critical, major and minor defects?
Critical defects affect safety or legal compliance, such as a wrong allergen statement. Major defects affect function or acceptance, such as unreadable barcodes or colour out of limit. Minor defects are cosmetic. Your customer specification defines the classes.
Do I need customer approval to use nonconforming packaging?
Usually yes for product supplied to a customer, particularly when specifications or artwork are involved. Obtain a written concession and record it on the NCR. Do not rely on verbal agreement.
What should be done with a defect found after shipment?
Contain stock at both sites, notify the customer immediately, trace the lot to find what else shipped and agree return, sort or replacement. Record all of it on the NCR and open a corrective action.
How is an NCR different from a CAPA?
An NCR documents a specific nonconforming product and its disposition. A CAPA addresses the cause to prevent recurrence and may be opened from one or many NCRs. Many plants reference the CAPA number on the NCR.
If NCRs are paper forms, we can help link them to lot records and quality holds in your ERP so affected stock is blocked automatically.
Related Tools
Press Check Sign-Off Sheet Template
A press-side OK-to-run sheet that records measured values, colour decisions and who approved the sheet before the full run starts.
Industry TemplatesPackaging Artwork Proof Approval Form Template
A fill-in artwork approval form that captures version, colour, barcode and legal copy checks plus sign-offs before plates or cylinders are made.
Supply Chain & InventoryPackaging Supplier Scorecard Worksheet
An editable scorecard that weights quality, on-time delivery, price, responsiveness and compliance into one score per packaging supplier.
MES & Shop FloorPrint Press Run Log Worksheet
An editable run log that computes total waste, waste percent and average run speed for every job on the press.
More Quality & Inspection tools
See all- Packaging Line Clearance and Label Reconciliation Checklist
- SAP QM Process Capability Cp Cpk Calculator
- SAP QM Lot Rejection Rate, PPM and Sigma Level Calculator
- SAP QM Gauge R&R Study Calculator
- SAP QM Cp and Cpk Capability Calculator
- Job Shop Material Certification Log Worksheet
- Job Shop First Piece Inspection Sign-Off Template
- Job Shop Scrap and Rework Cost Calculator
- Master Data Audit Sample Size Calculator