Casing Rejection Control

Casings inspected

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Reject rate

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First-pass yield

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accepted first time

Points out of control

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weeks beyond ±3σ

Total rejects

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carrying a code

Reject rate by week — p-chart with control limits

Weekly reject proportion vs the centre-line and ±3σ limits (limits widen when a week inspects fewer casings). Points outside the band are special-cause, not noise. Control limits recompute on your current filter; n small ⇒ wide limits.

Weekly throughput — accepted vs rejected

Casings inspected per week, accept / reject split

Top cause

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Top code

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Vital few

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codes driving 80% of rejects

Active codes

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distinct rejection codes

Rejection code Pareto

Each code's share of rejects (bars) + cumulative % (line) · dashed = 80% line · the vital few on the left

Cause mix

Share of rejects by root-cause family · click a slice to drill

Plant first-pass yield

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accepted first time

Worst station

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Best station

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Escapes at final

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rejects at final inspection

First-pass yield by station

Yield = 1 − rejects ÷ inspected, per station in process order · orange bar = worst · each casing is inspected at one station

Reject rate by department

Where rejects concentrate across the process · click to drill

Worst supplier

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Suppliers above plant avg

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worse than the mean

Plant reject rate

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baseline

Incoming casings

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from previous owners

Reject rate by previous owner

Worst 15 incoming suppliers by reject %, min. 30 casings · redder = worse

Supplier volume vs reject rate

Each dot a previous owner · x = volume · y = reject % · top-right = high-volume & high-reject = act first

Total scrap cost

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cost of poor quality

Scrap / inspection

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across all casings

Costliest cause

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Scrap vs rework

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structural vs surface

Scrap cost Pareto — by cause

Total £ scrap by cause (bars) + cumulative % · this re-ranks vs the count Pareto — the most frequent defect is not the most expensive

Scrap cost by station

Where the money is lost across the process

Concentration (Gini)

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across cause × department

Open CAPAs

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corrective actions

CAPA closure

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rejects with closed action

Fix first

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highest frequency × cost

Defect concentration — cause × department

Reject count per cause × department · darker = more · is it one cell or spread everywhere?

Corrective-action priority

Each dot a code · x = reject frequency · y = scrap £ · top-right = fix first · size = open CAPAs

Worst shift

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Shift spread

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best → worst (pp)

Worst retread level

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Inspector spread

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find-rate range (pp)

Reject rate by shift

A / B / C · night shift typically finds — or makes — more rejects

Reject rate by retread level

Higher retreads carry more risk · dashed = plant average

Reject rate by inspector

Find-rate per inspector vs the plant average (dashed) · variation in inspection, not necessarily fault · min. 30 inspections

Defect records

Aggregated on current filters · click a header to sort · click a row to filter

Group by

Group	Inspected	Rejects	Reject % ▼	Scrap £