Defects, Causes & Rectification.

Types of Defects.

1. Critical — is one likely to result in hazardous or unsafe conditions for the people who use the product or service. (defective brakes on a car)
2. Major — is one likely to result in a failure or reduction in the use of the product or service. (blocked spray nozzle)
3. Minor — is one that is likely to have little or no effect on the use of the product or service (loose thread)
4. Incidental — is one that has no effect on the use of the product or service. (Knot in wood)

Causes of Defects.

1. Operator error — Inadvertent – Lack of attention/care/tiredness.
2. Technique – Lack of Knowledge/training/skill
3. Change of Conditions in a Process. — Poor maintenance of equipment.
4. Change of Materials — Specification of raw materials, components or services lowered for cost cutting, lack of resources

Rectifying Defective Products.

1. Investigate Cause — Unsatisfactory tool & equipment, materials, ill trained operators. Unsatisfactory production methods, Quality Control, Product Design.
2. Recommend Solution — Improve Tool, equipment, machines & Quality Control. Alternative/better materials & improve design. Improve training.
3. Re-work — Correct product to meet specification.
4. Scrap — Scrap materials, components, products or services that can not be reworked, used for an alternative purpose or recycled.
5. Downgrade. — Lower specification. Sell as “Seconds”.