Quality Control & Defect Analytics

Real-time monitoring of COPQ, FPY, and systemic defect patterns

Last Updated
Dec 28, 2024 14:35
COPQ % Revenue
3.2%
-0.9pp vs Q3
First Pass Yield
94.7%
+1.2pp
DPMO
12,500
3.7σ Level
SPC Violations (30d)
42
+8 vs prev
Material Accept Rate
96.8%
+0.5pp
Customer PPM
285
-42 PPM
Rework % Hours
4.3%
-0.8pp
CAPA Recurrence
18.5%
-3.2pp
Cpk <1.0 Count
14
8.2% of chars
GR&R >30%
11.2%
-2.1pp
Total Defects (30d)
1,847
-156
Active CAPAs
27
19 overdue

Cost of Poor Quality Breakdown

First Pass Yield by Process Stage

Defect Pareto Analysis (Top 10 Failure Modes)

SPC Violations (90 Days)

Process Capability (Cpk) Distribution

Defect Heat Map: Machine × Material Type

Steel A2
Aluminum 6061
Titanium Ti-6
Composite CF
Plastic ABS
CNC-Mill-01
142
68
54
12
8
CNC-Mill-02
71
63
19
15
5
Lathe-A5
89
124
47
22
11
Lathe-B3
56
78
31
9
6
Grinder-G1
43
38
25
14
3
Assembly-01
27
34
18
62
71
Low (0-40)
Medium (41-100)
High (>100)

Top 10 Defect Contributors (Machine × Material × Defect Type)

Machine Material Defect Type Count COPQ Impact Trend
CNC-Mill-01 Steel A2 Dimensional Out-of-Spec 142 $47,320
Lathe-A5 Aluminum 6061 Surface Finish 124 $38,960
Lathe-A5 Steel A2 Burr/Sharp Edge 89 $22,470 —
Lathe-B3 Aluminum 6061 Thread Quality 78 $28,180
CNC-Mill-02 Steel A2 Tool Mark 71 $17,040
Assembly-01 Plastic ABS Assembly Misalignment 71 $21,300
CNC-Mill-01 Aluminum 6061 Dimensional Out-of-Spec 68 $19,040 —
CNC-Mill-02 Aluminum 6061 Chatter Mark 63 $15,120

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