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Defect Reason#

A Defect Reason tracks quality issues or anomalies found on Materials during production. Unlike a Loss Reason, a Defect Reason does not reduce Material quantity automatically.

Defect Reasons help you:

  • Track specific quality issues on Materials.
  • Record defect location and severity.
  • Support detailed quality analysis.
  • Improve traceability of quality problems.
  • Enable process improvement initiatives.
Aspect Defect Reason Loss Reason
Purpose Track specific quality issues Record quantity reduction
Quantity impact Does not change quantity automatically Reduces Material quantity
Location tracking Can record an exact location Does not track location
Multiple records Supports multiple defects per Material Supports multiple losses per Material
Main use case Quality analysis and traceability Yield calculation and scrap tracking

Recording a defect does not reduce Material quantity automatically. If the Material must be scrapped because of the defect, mark it as Not Fixable.

Configure a Defect Reason#

  1. Open the Reason module and create a new Reason.
  2. Select the Defect type.
  3. Optionally select a category from ReasonCategory.

  4. Select Create.

    Defect reason configuration page

  5. Define the repair actions by selecting Manage Repair Actions.

    Manage Repair Actions option

  6. Configure the repair actions:

    • Enter a name for the repair action.
    • Optionally enter a description.
    • Set the replacement mode to Allowed, Not Allowed, or Required.
    • Select Update.

    Repair actions configured for the defect reason

  7. Assign the Defect Reason to the Coating Step and confirm that the repair actions are visible.

    Repair actions visible after assigning the defect reason

  8. If the part replacement mode is Required, define the default BOM at the Product level.

    Product configuration with the default BOM

  9. Define the Defect Repair Policy at the Product level.

    Defect repair policy on the product

    Product policy details for defect repair

Scenario: Record and Manage Defects#

  1. Open the Engine Block H08-P9.011 Material details page.
  2. Go to Views > Defects.

  3. Select Record Using Picture.

    Defects page with the Record Using Picture action

  4. Upload a picture and select Next.

  5. Select the Defect Reason. The list shows only Reasons of the Defect type.
  6. Optionally select a part number if the replacement was planned in the part replacement mode.

  7. Optionally add a remark and select Record.

    Defect recording wizard with picture-based entry

  8. Review the available actions in the ribbon:

    • Mark the defect as Accepted
    • Mark the defect as False
    • Mark the defect as Scrap
    • Apply the repair action ReplaceContaminatedArea
    • Mark the defect as Not Fixable