Shop Floor Quality Control & Defect Reduction

Precision Dynamics Manufacturing Co. • AS9100D Certified • 13-Week Rolling Period

COPQ % of Revenue

8.4%

↓1.8% vs 13w ago

Monthly COPQ

$371K

Target: $264K (6.0%)

Total DPMO

3,847

↓14% vs 13w ago

Avg Cpk (Critical CTQs)

1.21

Below 1.33 target

Escape Rate

1.8%

18 units to customer

First-Pass Yield

91.2%

↑2.4% vs 13w ago

Cost of Poor Quality Waterfall — Monthly Breakdown

Defect Pareto by Code (Last 30 Days)

Defect Rate by Shift

SPC Control Chart — Bore Diameter (Cell 3, Part Family 3)

Target: 25.000 mm ±0.015 mm • UCL/LCL: 25.010/24.990 mm • Cpk recovering post-insert replacement (Week 10)

Cpk Trend by CTQ (Last 13 Weeks)

Wk 1

Wk 5

Wk 9

Wk 13

Bore Dia

1.08

1.16

1.24

1.29

Surface Finish

1.41

1.38

1.42

1.44

Perpendicularity

1.22

1.25

1.28

1.33

Hardness

1.52

1.49

1.51

1.54

Cpk ≥ 1.33 (Excellent)

1.00–1.32 (Adequate)

< 1.00 (Unacceptable)

Rework Labor Hours by Defect Code

Supplier Quality DPMO (Top 5)

First-Pass Yield by Material Lot

Containment Effectiveness Rate (Last 13 Weeks)

Gauge R&R Status by Measurement System

Measurement System	Part/Characteristic	Last Study Date	GRR %	Status	Next Due
CMM-001	Bore Diameter (CTQ)	2024-02-14	8.2%	Excellent	2024-08-14
SJ-410	Surface Finish Ra	2024-01-22	12.4%	Adequate	2024-07-22
CMM-002	Perpendicularity GD&T	2024-03-05	9.1%	Excellent	2024-09-05
RB-3000	Hardness HRC	2024-02-28	6.7%	Excellent	2024-08-28
MIC-7500	Thread Pitch Diameter	2023-11-18	18.9%	Marginal	2024-05-18
PRO-5K	Profile Tolerance	2024-01-10	14.5%	Adequate	2024-07-10
OGP-ZIP	Hole Position XY	2024-03-12	7.8%	Excellent	2024-09-12
CAL-450	Caliper OD Meas	2023-10-03	31.2%	Unacceptable	2024-04-03 (OVERDUE)