AI CAPA Workflow Management Agent

How Cassidy automates 8D / Nonconformance Response using AI

Step 1: Trigger on new nonconformance

The Workflow activates when an NCR, customer complaint, SCAR, or audit finding enters your QMS—whether from in-process inspection, end-of-line test, warranty return, or supplier escape.

Step 2: Classify and triage

Cassidy uses NLP to parse the defect description, auto-assign defect codes and suspected stations, link related events, and calculate an initial Action Priority score using AIAG/VDA logic. High-severity issues automatically trigger stop-ship holds in MES.

Step 3: Launch containment tasks

Based on defect type and severity, Cassidy generates a containment checklist—lot quarantine, 100% sort, rework instructions—and assigns tasks to the cross-functional 8D team with SLA-driven reminders.

Step 4: Guide root cause analysis

Cassidy pulls process parameters, SPC streams, maintenance logs, supplier CoAs, and prior 8D records into a unified view. Its 5-Why copilot proposes hypotheses, prompts for evidence, and ensures both occurrence and escape causes are addressed.

Step 5: Plan and approve corrective actions

The Workflow templates D6 tasks—process changes, Poka-Yoke, training, PFMEA/Control Plan updates—with owners, due dates, and e-signature approvals. Cassidy flags which FMEA entries need revision and drafts updated Action Priority assessments.

Step 6: Verify effectiveness

Cassidy builds a verification plan with defined metrics (PPM, Cp/Cpk, complaint rate), baselines, and pass/fail thresholds. It monitors production data over the effectiveness check window and alerts if metrics regress—preventing closure until all criteria are met.

Step 7: Close and propagate lessons learned

Once verification passes, Cassidy archives the complete 8D record with audit trail and e-signatures, pushes updates to PFMEA/Control Plans, and indexes the corrective action in the Knowledge Base so similar issues across products or processes can reuse proven fixes.