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Chapter 16: C. Inspection Planning and Procedures 177
the term nonconformity and the term defect is based mainly on the perspective.
The former is defined based on specifications, while the latter is defined based
on fitness for use. Thus, the numerical result generated by inspection consists of
the count of defects or nonconformities for each product unit. Often it is possible
to classify the different types of defects according to their severity, then assign a
weight to each class based on the importance of the affected quality characteristic
in terms of the product specifications. The selection of the weights should reflect
the relative importance of the various defect categories and their likelihood of
causing product failure or customer dissatisfaction. A typical seriousness classification
includes four levels of defect severity:
1. Critical defect. May lead directly to severe injury or catastrophic
economic loss.
2. Serious defect. May lead to injury or significant economic loss.
3. Major defect. May cause major problems during normal use.
A major defect will likely result in reducing the useability of
the product.
4. Minor defect. May cause minor problems during normal use.
Training programs should be periodically aimed at new inspection personnel as
well as those with on-the-job experience. On-the-job training by a supervisor or
a training coordinator could be the most convenient and least costly approach to
training. Other training methods include:
• Classroom instruction by in-house experts or outside consultants.
This is best suited for theoretical subjects, such as basic mathematics,
statistics, experimental design, and computer use.
• Self-study using audiovisual programs and self-instruction training
manuals. This method allows the inspectors to study at their own pace
and during convenient times.
• Outside programs offered by professional organizations and their
local chapters, and by universities and community colleges through
their extension divisions.
Part III.C.6
6. REPORTING OF NONCONFORMING MATERIAL
Describe the reporting of nonconforming
material for disposition, such as Material
Review Board (MRB), rework, reprocess,
scrap, and customer waiver. (Application)
Body of Knowledge III.C.6