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Why do parts that passed inspection come back?
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THE QUESTION

Why do parts that passed inspection come back?

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Temperature in the shop swings fifteen degrees between morning and afternoon
also discussed during · Clarify (1) · Cluster (1) · Map (1)
Nothing said yet.
Packaging damages parts that were fine when they left the machine
Quotes are won on price, so cycle times are cut to the bone
I mean this is how it goes most weeks.
Operators are paid on parts per hour
Temperature in the shop swings fifteen degrees between morning and afternoon
Coolant is changed when it smells, not on a schedule
Batch traceability ends at the door
Rework is not counted anywhere
Scope: our shop, not the customer's line.
cluster 5discuss
The same operator runs the same machine for years and nobody checks the settings
Night shift has no inspector
Sales promises tolerances the machines cannot hold reliably
Scrap is thrown in the skip before anyone measures it
cluster 5discuss
A returned part is remade, not investigated
Meaning the repeat returns, not the one bad batch in spring.
The drawing on the floor is not the revision the customer ordered
The oldest machine makes the tightest-tolerance part
Customers changed their inspection method and never told us
Material certificates are filed but never read
Setup sheets are in the setter's head, not on paper
cluster 1discuss
Tool wear is judged by ear
Meaning the repeat returns, not the one bad batch in spring.
cluster 3discuss
The customer's returns log and ours do not match
Meaning the repeat returns, not the one bad batch in spring.
Deburring is done by whoever is free
The one person who can read the CMM output left last year
I mean this is how it goes most weeks.
cluster 1discuss
New jobs are quoted from the last similar job, not from the drawing
I mean this is how it goes most weeks.
Parts that pass our inspection fail the customer's
Maintenance is done when a machine stops
cluster 2discuss
Our gauges are calibrated once a year, theirs every month
Meaning the repeat returns, not the one bad batch in spring.
cluster 4discuss
First-off inspection is skipped when the job is late
Meaning the repeat returns, not the one bad batch in spring.
Nobody has asked the customer what they measure
cluster 4discuss