Receiving a failing inspection report is never a happy occasion Shipment delays, rework costs, etc. all create tension among all parties involved. But, put into perspective, the end result can be positive. When you see the “reject” status on the report, stay calm. Attack the problem with three questions:
Why did it fail?
Review the report carefully to determine what the issue(s) are. Was the failure of the result of one or more problems? How close were the defects from being within the AQL (Acceptable Quality Levels)?
How are we going to fix this?
Based on the information in the report, you can evaluate whether or not the product specifications should be modified and confirm that you’re comfortable with the AQL.
The factory is usually working on resolving the issues when the inspector reviews the results. A reinspection is often requested to confirm that everything has been resolved.
How do we prevent it from happening again?
Communication with the factory is key when planning corrective action. Identifying the root cause of the issue and documenting a resolution should prevent similar occurrences.