Upgrade the shop-floor habit of "tossing rejects in the corner" to "every defect registered, classified, root-caused and improved." A defect-code library unifies terminology, Pareto charts automatically surface the top defects, and the three disposition closures — rework / scrap / concession acceptance — are fully traceable.
A complete workflow from discovery to improvement
Scan-to-register on a PDA, capturing quantity, defect code, responsible operation, responsible operator, equipment, batch and more
Classified and graded defect codes (e.g. Appearance – Scratch – over 5mm), with plant-wide unified terminology to avoid ambiguity
Reworkable items convert to a rework work order, run back through the operations along the rework route, with rework hours separately allocated
Unsalvageable items go through a scrap request + finance approval + physical destruction, with scrap cost booked into work-order cost
Defects within the customer's acceptable range can be accepted by concession, with customer sign-off + price deduction + tagged segregation
Pareto charts are auto-generated by defect code / responsible operation / equipment / team, making the top 3 problems obvious at a glance
Without standard defect codes, operation A writes "corner damage," operation B writes "edge chip," and operation C writes "edge break" — the same problem never adds up in the statistics. SBK MES enforces a unified defect-code library so everyone registers by code.
Defect count descending (pcs)
Defects come in many types, and limited resources can't fix them one by one. The Pareto chart sorts defects by count in descending order — the top 20% of defects typically account for 80% of rejects, so investing improvement effort here yields the highest ROI.
Defects aren't just registered and set aside — they must have a clear disposition outcome. All three methods — rework / scrap / concession acceptance — have explicit workflows and approvals, with material whereabouts clearly traceable.
OEMs require PPM <50; every defect is registered and a monthly PPM report is produced per customer
BGA cold-joint items are tagged and segregated, converted to a rework work order through X-Ray + reflow operations, traceable per board
Minor cosmetic flaws on non-critical surfaces can be accepted by concession, with the price deducted after the customer signs off online
Near-expiry / expired products go through the scrap workflow + video destruction record, available for regulators to inspect at any time
From inspection to defect handling to traceability and improvement — a complete quality loop
Inspection NG items automatically enter the defect workflow
SPC anomalies link to defect analysis
Defects link to batches for easy traceability
Scrap / concession go through the OA approval workflow
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