What happens in the plant
- Scrap is recorded as a total without enough reason context
- Rework is tracked separately from the production event that created it
- Quality loss is reviewed after the order is complete
- Defect reasons are not tied to line, shift, asset, product, or inspection result
- Corrective actions are assigned late or not followed to closure
Why it matters
Scrap and rework reduce output, consume material, hide process instability, and distort performance reporting. If teams only see the final reject total, they cannot tell whether the issue is process drift, operator setup, equipment condition, material variation, or inspection delay.
What teams need to see
Teams need to see scrap quantity, rework quantity, reason, product, lot, line, shift, source process, inspection result, owner, and corrective action status.
Decisions this problem affects
- Which defect reason is creating the most recoverable loss?
- Which product, line, or shift shows recurring rework?
- Which quality issue needs containment before more material is consumed?
- Which corrective action owner should be escalated?
- Which scrap pattern should be reviewed in the daily production meeting?