THE QUESTION
Why do parts that passed inspection come back?
Group cards you judge alike. Groups organise reading; they decide nothing.
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Clusters form from similarity, names come last
Canonical order: link pairs of ideas you judge similar — links are symmetric (A~B is B~A; direction never matters) and a tie holds once 2 members make it.
why
Links are symmetric — A~B is B~A. Clusters are the groups that emerge from held ties, and only a formed cluster can be named, by a person. Your own links carry a ✕ to withdraw; you cannot remove someone else's. Clusters organise the wall and never gate the vote — two cards making the same CLAIM are a merge back in Clarify.
Links and names are made while Cluster is live; the steward’s ← reopens it.
unnamed cluster — name it if the group has a common thread, or leave it unnamed (2)
Maintenance is done when a machine stops
~ Packaging damages par…Packaging damages parts that were fine when they left the machine (14)
Packaging damages parts that were fine when they left the machine
~ Maintenance is done w…Maintenance is done when a machine stops (14)
unnamed cluster — name it if the group has a common thread, or leave it unnamed (2)
Coolant is changed when it smells, not on a schedule
~ Tool wear is judged b…Tool wear is judged by ear (12)
Tool wear is judged by ear
~ Coolant is changed wh…Coolant is changed when it smells, not on a schedule (12)
unnamed cluster — name it if the group has a common thread, or leave it unnamed (2)
The one person who can read the CMM output left last year
~ Setup sheets are in t…Setup sheets are in the setter's head, not on paper (12)
Setup sheets are in the setter's head, not on paper
~ The one person who ca…The one person who can read the CMM output left last year (12)
unnamed cluster — name it if the group has a common thread, or leave it unnamed (2)
Rework is not counted anywhere
~ Scrap is thrown in th…Scrap is thrown in the skip before anyone measures it (17)
Scrap is thrown in the skip before anyone measures it
~ Rework is not counted…Rework is not counted anywhere (17)
unnamed cluster — name it if the group has a common thread, or leave it unnamed (2)
Nobody has asked the customer what they measure
~ Our gauges are calibr…Our gauges are calibrated once a year, theirs every month (17)
Our gauges are calibrated once a year, theirs every month
~ Nobody has asked the …Nobody has asked the customer what they measure (17)
· not yet clustered (17)
The customer's returns log and ours do not match
Sales promises tolerances the machines cannot hold reliably
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
Quotes are won on price, so cycle times are cut to the bone
The drawing on the floor is not the revision the customer ordered
The oldest machine makes the tightest-tolerance part
Material certificates are filed but never read
First-off inspection is skipped when the job is late
Parts that pass our inspection fail the customer's
A returned part is remade, not investigated
Customers changed their inspection method and never told us
Operators are paid on parts per hour
Temperature in the shop swings fifteen degrees between morning and afternoon