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Defect Management

Defect Management · Defect Codes & Pareto Analysis

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.

Disposition Methods (Rework / Scrap / Concession)

Unified Defect-Code Library

80/20

Pareto Finds the Top Problems

Capabilities

Core Capabilities of Defect Management

A complete workflow from discovery to improvement

📝 Defect Registration

Scan-to-register on a PDA, capturing quantity, defect code, responsible operation, responsible operator, equipment, batch and more

📚 Defect-Code Library

Classified and graded defect codes (e.g. Appearance – Scratch – over 5mm), with plant-wide unified terminology to avoid ambiguity

🔧 Rework Workflow

Reworkable items convert to a rework work order, run back through the operations along the rework route, with rework hours separately allocated

🗑 Scrap Workflow

Unsalvageable items go through a scrap request + finance approval + physical destruction, with scrap cost booked into work-order cost

📥 Concession Acceptance

Defects within the customer's acceptable range can be accepted by concession, with customer sign-off + price deduction + tagged segregation

📊 Pareto Analysis

Pareto charts are auto-generated by defect code / responsible operation / equipment / team, making the top 3 problems obvious at a glance

mes.shangbangke.com/defect/codeCode library

Defect-Code Library

ImportNew request

Code3-level classSeverity

A-01-03Appearance→Scratch→>5mmMajor

A-02-01Appearance→Chip→EdgeMinor

B-01-02Dimension→Oversize→ODCritical

C-03-01Function→Fail→OpenCritical

Defect-Code Library: Give "Quality Problems" a Common Language

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.

Three-level classification: major → middle → minor (Appearance → Scratch → length > 5mm)
Each defect is bound to a standard image library for easy operator recognition
Defect severity grading (critical / major / minor / cosmetic)
New-defect requests go through approval, preventing chaos from arbitrary expansion

mes.shangbangke.com/defect/pareto80/20

Defect Pareto — Week 21

DrillExport

1,284Total defects

3Top 20%

79%Cumulative

↓12%vs prev

Defect count descending (pcs)

412Scratch

318Oversize

268Chip

146Warp

94Other

Pareto Chart: Use 80/20 to Find the Most Worthwhile Problems

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.

Slice by defect code / operation / equipment / team / operator
Cumulative-percentage line marks the top-20% threshold
Drill-down analysis: click a top defect to see the specific batch and sample photos
Before/after comparison: verify the effectiveness of countermeasures

mes.shangbangke.com/defect/disposalTraceable

Defect Disposition

DetailSubmit approval

LotDispositionQtyStatus

LOT-2041Rework order RW-30132Reworking

LOT-2043Scrap · OA approval8Pending

LOT-2049Concession · signed15Released

LOT-2055Scrap · written off6Done

Disposition Workflow: Rework / Scrap / Concession Fully Traceable

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.

Rework work orders coded separately, with rework hours / materials allocated independently
Scrap requests go through OA approval, including finance, quality and shop-floor sign-off
Concession acceptance requires written customer consent, with materials tagged and segregated
Scrap cost allocated to the work order / responsible operation / responsible supplier

Use Cases

Defect Management in Action Across Industries

Auto Parts PPM Tracking

OEMs require PPM <50; every defect is registered and a monthly PPM report is produced per customer

SMT BGA Cold-Joint Rework

BGA cold-joint items are tagged and segregated, converted to a rework work order through X-Ray + reflow operations, traceable per board

Injection-Molding Cosmetic Concession

Minor cosmetic flaws on non-critical surfaces can be accepted by concession, with the price deducted after the customer signs off online

Food Expiry Destruction

Near-expiry / expired products go through the scrap workflow + video destruction record, available for regulators to inspect at any time

Related Features

How Defect Management Connects with These Capabilities

From inspection to defect handling to traceability and improvement — a complete quality loop