Measure how often production creates nonconforming output.
Defect rate tracks how frequently products or process results fail defined requirements. Useful analysis separates defect type, source, severity, product, machine, tooling, recipe, shift, and process condition so recurring patterns can be found.
Track the losses that consume capacity without creating good output.
Rework, defects, process variation, inspection, scrap, and yield should be tied back to the production conditions that created them.
Move from detection toward prevention.
Inspection is necessary, but the larger gain comes from making the process stable enough that fewer defects are created in the first place.
CRIT-AUse Consistent Categories
Defect names and classification rules should remain stable enough to compare performance over time.
Related Guide →CRIT-BAdd Process Context
Machine, tool, cavity, batch, recipe, and shift data often reveal patterns that a total defect count cannot.
Related Guide →CRIT-CPrioritize by Impact
Frequency, severity, scrap value, rework time, and customer risk can point to different priority defects.
Related Guide →CRIT-DVerify Corrective Action
A defect should remain under review long enough to confirm the corrective action changed the underlying pattern.
Related Guide →Visualize the quality loss and process behavior.
These diagrams separate recurring quality loss from overall process stability and improvement trend.
Loss trend.
Track recurring quality loss over time to see whether changes are reducing the problem.
Process stability.
Stable process behavior supports better yield and fewer quality escapes.
Relevant inspection and measurement resources.
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