Manufacturing Defect Analytics & Root Cause Guides
Deep-dive analytics guides for the defect types that drive the most scrap in discrete manufacturing — with root causes, detection methods, and reduction strategies.
Primary Defect Types
- Dimensional Deviation & Out-of-Tolerance Rejection~35% of total scrap eventsThe manufactured part's dimensions fall outside specified tolerances — length, width, height, diamet…
- Surface Defects (Scratches, Marks, Finish Failures)~22% of total scrap eventsImperfections on the visible or functional surface of a part — scratches, dents, pits, porosity at t…
- Contamination & Foreign Material~18% of total scrap eventsThe presence of foreign material in or on the product — metallic chips, cross-contamination from a p…
- Assembly Errors (Wrong Part, Missing Component, Incorrect Build)~8% of total scrap eventsDefects arising during assembly operations — wrong part installed, missing component, incorrect orie…
- Weld Defects (Porosity, Incomplete Fusion, Cracking, Distortion)~7% of total scrap eventsDefects in welded joints — porosity, lack of fusion, undercut, cracking, excessive spatter, and dist…
- Packaging Defects (Seal Failures, Label Errors, Fill Deviations)~15% of total scrap eventsDefects in the packaging of finished product — failed seals on flexible packaging, label misregistra…
- Material Rejection (Incoming Quality Failure)~10% of total scrap eventsRaw material or purchased components that fail incoming inspection and must be rejected, scrapped, o…