Quality Defects
A product that does not meet customer requirements.
What is a defect?
This report is commonly used to solve customer quality problems.
What is an 8D Report?
LPA stands for this type of audit.
What is a Layered Process Audit?
This inspection checks the first product after a setup or changeover.
What is First Piece Inspection?
Name the five steps of 5S.
What are Sort, Set in Order, Shine, Standardize, and Sustain?
Dirt, metal chips, plastic, or any unwanted object found on a product.
What is foreign material?
This tool asks "Why?" several times to find the real cause.
What is the 5 Why Analysis?
This document tells what to inspect and how often.
What is a Control Plan?
This Japanese word means "mistake-proofing."
What is Poka-Yoke?
PPE stands for this.
What is Personal Protective Equipment?
A part that is missing a required component.
What is a missing component?
This diagram helps organize possible causes of a problem.
What is a Fishbone (Ishikawa) Diagram?
This document identifies possible process failures before they happen.
What is a PFMEA?
This document explains the correct way to perform a job.
What is a Work Instruction?
To prevent slips, falls, and injuries.
Why should spills be cleaned up immediately?
A product that has scratches, dents, cracks, or other visible damage.
What is cosmetic damage?
This cycle stands for Plan, Do, Check, Act.
What is PDCA?
This standard is the quality management system used by the automotive industry.
What is IATF 16949?
Stop, Call, Wait: Stop the process, contain the product, and notify your Team Lead or Supervisor.
What should you do if you find a defect during production?
Report it immediately and follow company procedures.
What should you do if you see an unsafe condition?
A defective product that reaches the customer.
What is a customer escape?
This process focuses on preventing a problem from happening again.
What is Corrective Action?
Products that do not meet requirements must be identified and separated.
What is control of nonconforming product?
It helps ensure every product is made the same way every time.
Why is standard work important?
It improves safety, quality, and efficiency.
Why is a clean and organized work area important?