Defect List vs. Checkpoint List - QualityInspection.org

I noticed many people confuse two things: the list of potential defects, and the list of checkpoints to follow during an inspection. Youarehere:Home/QualityControlTips/DefectListvs.CheckpointList Inoticedmanypeopleconfusetwothings:thelistofpotentialdefects,andthelistofcheckpointstofollowduringaninspection. WhatIseeveryoftenisalistofpotentialdefects,butnolistofcheckpoints. Thereare2mainproblemswiththis: Theinspectorhasnostructuretofollow. Whenrandomsamplingisused,theinspectorshouldNOTcounteveryproblemhefindsasadefect.Ifhechecksapointonthefullsamplesize(forexampleon200pcs),that’sfine.Butthisisnotvalidifheonlychecksafewsamplesforacertainpoint.Itwouldmeanthestatisticsaretwisted. Hereareacoupleof examplestoillustratethissecondpoint: Theexportcartonweightisusuallycheckedonlyonafewcartons.Notonallselectedcartons.Ifafewcartonshavethewrongweightanddonotconformtothebuyer’sspecs,noneedtocheckallcartons.Theinspectionresultis“onhold”or“failed”. Settinganelectricalwidgetonandthenoffcanusuallybedoneonallinspectedsamples.Soitmakessensetocounteverynon-functioningwidgetasadefect(usuallywithmajorseverity).   Whatisa listofpotentialdefects? Itisareminderfortheinspectorwhenitcomestothevisualcheck. Itsetsthequalitystandardandreducestheprobabilityofaheatedconversationbetweenthefactoryandtheinspector.Agooddefectlistshowstheseverity(critical/major/minor)ofeachtypeofdefect.Andthebestdefectlistsalsoillustrate(withphotosifpossible)whatthelimitisbetweenadefectandanon-defect. Itcannotbeexhaustive.Theremight alwaysbenewtypesofdefects. Theinspectorsumsupthedefectshe/shehasfound.Forrandominspections,he/shecomparesthemtothe AQLlimits. Itusuallylookslikethis: Whatistheproblemifyouonlyprepareadefectlist?Youleavealotofroomtotheinspectortodecidehowheisgoingtoorganizehisinspectionandhowitwillbeperformedinthedetails.Andyouarefoolingyourselfifyouimaginehe’sgoingtochecktheweightofeverycarton(forexample)! Whatarethe3mostcommoncategoriesofdefects? AmericannationalstandardASQ/ANSIID1:2021suggeststhese3categories: Critical–mayleaddirectlytosevereinjuryorcatastrophiceconomicloss. Major–maycausemajorproblemsduringnormaluse.Amajordefectwilllikelyresultinreducedusabilityoftheproduct.Itmayalsoleadtoinjuryorsignificanteconomicloss. Minor–maycauseminorproblemsduringnormalusesuchasnoiseorvibration.   Whatisa listofcheckpoints? Itguides theinspectorstepbystep.Itisakindofto-dolist. Theinspectorhastotickeachpoint,ashegoesthroughtheinspection.Thereisnowaytoforgetonepoint,andnoexcuseshouldproblemsbefoundlater. Itcarriesmoreinformationthanadefectlist.Itspecifieswhattodo,withwhatsettings,whatexactresultisexpected,whatequipmenttouse,etc. Apointcanbecheckedonthewholesamplesize(especiallyifittakeslittletimeanditisveryimportant)oronasmallersample. Incaseapointischeckedonthewholesamplesize,aproblemcanbecountedasadefect.Thereisoverlapherebetweenthetwodocuments. IncaseapointisNOTcheckedonthewholesamplesize,aproblemissimplycountedascritical.Thatcheckpointisfailedoronhold,andthewholeinspectionreportisfailedoronholdforthatreason. Itusuallylookslikethis: Oritcanbeaverysimplechecklist,usedoveranumberofdifferentproducts,thatlookslikethis:   ***** Someinspectioncompaniestrytoapply theAQLtablestoeverythingtheycan,includingtothesizecheckofgarments.ItispossiblebutIamnotafanofthatapproach,asIwrotehere. Whatistheproblemifyouonlypreparealistofcheckpoints?Youleavealotofroomtotheinspectortodecideontheseverityofthedefectshefinds. ***** IhopeImadethedifferenceclear.Any questionsorremarks?   Sofeast:QualityAssuranceInChinaOrVietnamForBeginners[eBook] ThisfreeeBookshowsimporterswhoarenewtooutsourcingproductiontoChinaorVietnamthefivekeyfoundationsofaprovenQualityAssurancestrategy,andalsoshowsyousomecommontrapsthatimportersfallinto and howtoavoidorovercometheminordertogetthebestpossibleproductionresults. Readytogetyourcopy?Hitthebuttonbelow: Weeklyupdatesforprofessionalimportersonbetterunderstanding, controlling,andimprovingmanufacturing&supplychaininChina. ThisistheofficialblogofSofeast.com. ThisblogiswrittenbyRenaudAnjoran,anASQCertifiedQualityEngineerwhohasbeeninvolvedinchinesemanufacturingsince2005. Hitthebuttonbelowtogetintouch: ContactUs! Subscribetoouremailnewsletter Connectwithus EmailFacebookLinkedInRSSTwitterYouTube LatestArticles TheNewApparelDevelopment&ProductionProcess[Podcast] Goingfrom1PrototypetoMassProductiondirectlyisDangerous ShouldNorthAmericanImportersLeaveChinaForCountriesLikeMexicoorVietnam?(Feat.AndrewHupert)[Podcast] InspectingProductionswithVeryFewDefects:DumptheAQL AnsweringYourQuestionsonFabricQuality,USTariffs,&VolatileMaterialPrices. 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