Quality & Defect Intelligence

First-Pass Yield
96.3%
+0.8%
Defect Density
2.8
per 1K units
+0.3
Cost of Quality
4.2%
of revenue
+0.4%
Rework Hours
1,247
last 4 weeks
+112
Scrap Rate
1.6%
of production
-0.2%
Customer Complaints
38
this month
-6

Defect Pareto — Top 10 Categories (Last 8 Weeks)

Cost of Quality Waterfall

Supplier Material Rejection Rate

Rework Hours & Scrap Cost Heatmap by Product Family × Week

W1
W2
W3
W4
W5
W6
W7
W8
W9
W10
W11
W12
65W Adapters
87h
$4.2K
92h
$4.5K
112h
$5.8K
138h
$7.1K
164h
$8.9K
171h
$9.3K
118h
$6.1K
96h
$4.8K
89h
$4.4K
84h
$4.1K
76h
$3.7K
72h
$3.5K
USB-C Hubs
54h
$2.1K
58h
$2.3K
61h
$2.4K
73h
$2.9K
69h
$2.7K
62h
$2.4K
59h
$2.3K
56h
$2.2K
48h
$1.9K
44h
$1.7K
42h
$1.6K
39h
$1.5K
Docking Stations
67h
$3.8K
71h
$4.0K
74h
$4.2K
82h
$4.7K
79h
$4.5K
73h
$4.1K
69h
$3.9K
66h
$3.7K
63h
$3.6K
58h
$3.3K
55h
$3.1K
52h
$2.9K
45W Adapters
41h
$1.8K
38h
$1.7K
42h
$1.9K
46h
$2.0K
43h
$1.9K
39h
$1.7K
36h
$1.6K
34h
$1.5K
32h
$1.4K
29h
$1.3K
27h
$1.2K
25h
$1.1K
USB-A Hubs
32h
$1.2K
29h
$1.1K
31h
$1.2K
34h
$1.3K
36h
$1.4K
33h
$1.3K
30h
$1.1K
28h
$1.0K
26h
$1.0K
24h
$0.9K
22h
$0.8K
21h
$0.8K

Customer Complaint Trend by Category

Defect Distribution by Shift

CAPA Tracker

CAPA ID Title Category Root Cause Assigned Due Date Status
CA-2024-087 Line 4 Mold Alignment Drift Process Insert wear J. Martinez 2024-11-15 Closed
CA-2024-091 Supplier D PCB Substrate Defect Material Resin batch variance A. Chen 2024-12-01 Open
CA-2024-094 FJ-2024 Capacitor Field Failure Component Spec deviation R. Patel 2024-11-28 Open
CA-2024-079 USB-C Soldering Voids Process Flux contamination L. Kim 2024-10-20 Closed
CA-2024-083 Cosmetic Scuffing on Housing Handling Conveyor speed M. Torres 2024-11-10 Closed
CA-2024-096 Dimensional Variance in Shell Tooling Mold cavity wear J. Martinez 2024-12-05 Open
CA-2024-089 LED Indicator Misalignment Assembly Fixture drift K. Lee 2024-11-18 Closed
CA-2024-092 Electrical Test False Fails Equipment Probe contamination T. Nguyen 2024-11-25 Open
CA-2024-085 Cable Insulation Cuts Material Handling damage A. Chen 2024-11-08 Closed
CA-2024-098 Intermittent Power Output Design Component tolerance stack R. Patel 2024-12-10 Open
CA-2024-081 Label Adhesion Failure Process Surface preparation M. Torres 2024-10-30 Closed
CA-2024-095 Shipping Damage - Carton Drop Test Packaging Foam density spec L. Kim 2024-12-02 Open
CA-2024-088 Connector Retention Force Low Assembly Insertion depth variance J. Martinez 2024-11-12 Closed
CA-2024-097 Thermal Shutdown at Peak Load Design Heatsink sizing R. Patel 2024-12-08 Open