THE QUESTION
Why do parts that passed inspection come back?
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why
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merged "When a part comes back we just…" → "A returned part is remade, not…"
Maintenance is done when a machine stops
cluster 2discuss
The customer's returns log and ours do not match
Meaning the repeat returns, not the one bad batch in spring.
Sales promises tolerances the machines cannot hold reliably
Packaging damages parts that were fine when they left the machine
cluster 2discuss
Tool wear is judged by ear
Meaning the repeat returns, not the one bad batch in spring.
cluster 3discuss
Setup sheets are in the setter's head, not on paper
cluster 1discuss
The one person who can read the CMM output left last year
I mean this is how it goes most weeks.
cluster 1discuss
Deburring is done by whoever is free
Batch traceability ends at the door
Night shift has no inspector
The same operator runs the same machine for years and nobody checks the settings
New jobs are quoted from the last similar job, not from the drawing
I mean this is how it goes most weeks.
Scrap is thrown in the skip before anyone measures it
cluster 5discuss
Nobody has asked the customer what they measure
cluster 4discuss
Quotes are won on price, so cycle times are cut to the bone
I mean this is how it goes most weeks.
The drawing on the floor is not the revision the customer ordered
The oldest machine makes the tightest-tolerance part
Coolant is changed when it smells, not on a schedule
cluster 3discuss
Material certificates are filed but never read
First-off inspection is skipped when the job is late
Meaning the repeat returns, not the one bad batch in spring.
Parts that pass our inspection fail the customer's
A returned part is remade, not investigated
Meaning the repeat returns, not the one bad batch in spring.
Customers changed their inspection method and never told us
Our gauges are calibrated once a year, theirs every month
Meaning the repeat returns, not the one bad batch in spring.
cluster 4discuss
Operators are paid on parts per hour
Temperature in the shop swings fifteen degrees between morning and afternoon