Scrap reduction: locate defects within the process

Reducing scrap starts with a clear defect description. Linking defects to process steps prevents corrective action at the wrong point.

Use consistent defect categories

Distinguish dimensional deviations, surface defects and assembly errors. Record product, batch and time using the same structure. Data is difficult to compare if each shift uses different categories.

Separate detection from origin

The inspection station shows where a defect is detected, which may differ from where it originates. Trace the part through previous operations and review tool condition, material changes, fixturing and relevant process values. Sorting alone does not remove the cause.

Verify effectiveness

Test a defined intervention and document comparison conditions. A lower scrap rate is useful only if rework, inspection effort or defects elsewhere do not increase at the same time. Quality assurance should support the assessment.