Sheet Metal Nonconformance Report (NCR) Template
A nonconformance report records what went wrong, what was done about it and how recurrence will be prevented. This NCR template is tailored to fabrication defects like short flanges, burrs, bend angle errors and finish damage.
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Sheet Metal Nonconformance Report Template
Northline Metalworks - Nonconformance Report NCR-2026-0142
Date found: 2026-10-20 Job: WO-24817 Part: HE-2204-B rev C Quantity affected: 38 Found at: Press brake
Description of nonconformance
Flange length on bend 3 measured 0.8 mm short of tolerance on 38 pieces. Backgauge value was changed after a tooling swap.
Containment
Parts tagged and moved to quarantine rack. Remaining lot 100 percent checked at brake.
Root cause
Backgauge offset not reset after die change. Setup sheet lacked a first piece check on flange length.
Disposition
Scrap
Corrective and preventive action
Add flange check to first piece step on the setup sheet. Retrain brake operators on offset reset.
Cost and follow-up
| Item | Qty | Estimated cost | Owner | Due date |
|---|---|---|---|---|
| Scrapped parts | ||||
| Rework labor | ||||
| Corrective action task |
Approvals
A starting point for an internal quality record. If a customer quality agreement or standard such as ISO 9001 defines NCR contents or approval rules, follow those.
Track defects across lots and jobs
Optional: a short review of linking NCRs to ERP lots, work orders and suppliers.
Optional. The tool and every export work without this. No spam.
How to use the NCR
Complete the header and describe the defect with measured facts: which feature, how far out of tolerance, how many pieces. Record containment first, so suspect parts do not move on. Then document root cause and disposition. Finally write the corrective action with an owner and date. Export to PDF for the quality file and attach photos where possible.
Writing a useful defect description
Good descriptions state the requirement, the actual value and the quantity. Avoid vague wording like bent wrong. Name the feature by balloon or drawing zone. Include the job and operation where it was found, as well as where it was likely created, since defects often originate upstream of the point of detection.
- State requirement and measured value
- Give quantity affected and quantity checked
- Note the operation that created the defect
- Attach a photo or marked drawing
Root cause and corrective action
Ask why until you reach a process cause you can change, such as a missing check, a setup that is not reset or a drawing that is unclear. Retraining alone is a weak fix; pair it with a process change like a first piece step or a gauge. For repeat or customer-visible issues, consider a fuller method such as 8D.
Common mistakes
Teams often close NCRs with the disposition and skip the cause. Another issue is no containment, so suspect material is still on the floor. Also track cost: scrap and rework tallies show where the money goes and help justify fixes like better fixtures or gauges.
Frequently Asked Questions
What is the difference between an NCR and a CAPA?
An NCR documents a specific nonconformance and its disposition. A CAPA addresses the systemic cause to prevent recurrence. One NCR can trigger a CAPA, especially when defects repeat or reach the customer.
Who can approve use as is?
Your quality procedure should define it. For customer-specified parts, use as is usually needs customer approval. Never decide it on the floor without the documented authority.
Should I number NCRs?
Yes. A running number with the year makes records easy to find and lets you track counts, costs and trends over time.
Can I attach photos?
The template is text based. After exporting to Word you can paste photos into the document, or file images alongside the PDF using the NCR number.
If NCRs live in spreadsheets, we can help connect them to ERP lots and work orders so defect trends show up in reports.
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