8D report
A high-impact problem-solving method used to contain, correct, and prevent systemic quality issues.
Acceptance sampling
A statistical method to decide whether a lot is accepted or rejected based on a sample instead of 100% inspection.
AQL (Acceptance Quality Limit)
A statistical threshold that defines the maximum defect rate allowed before a lot is rejected.
Audit trail
A chronological record of every inspection event, result, and data change, providing clear proof for buyers.
Calibration
A controlled process for verifying and adjusting measurement devices so readings remain accurate and reliable.
CAPA (Corrective and Preventive Action)
A structured process for fixing the root cause of quality issues so they don't happen again.
CAR (Corrective Action Report)
A formal record describing a non-conformance, its root cause, and the actions taken to resolve it.
Check sheet
A structured form used to collect data in real time, often as part of the seven basic quality tools.
COC (Certificate of Conformity)
A document confirming that goods meet specified standards, regulations, or buyer requirements.
Containment action
Immediate actions taken to isolate suspect products and prevent further shipment or use of nonconforming items.
Control chart
A statistical chart used to monitor process stability over time and detect unusual variation.
Control plan
A documented roadmap describing how critical product or process characteristics will be monitored and controlled.
Cpk (Process Capability Index)
A statistical indicator showing how well a process stays within specification limits relative to its variation.
Critical to quality (CTQ)
Measurable product or process characteristics that have the highest impact on customer requirements.
Defect classification
A method for categorizing defects by severity and impact, typically as critical, major, or minor.
Defect escape
A defect that passes internal controls and reaches the next process, customer, or end user.
Deviation request
A formal request to temporarily ship or use material that does not fully meet specification under controlled conditions.
Dock audit
A verification check at shipping dock stage to confirm packaging, labeling, and shipment readiness before dispatch.
Dock-to-stock
A receiving strategy where incoming material moves directly to inventory without routine incoming inspection when supplier controls are trusted.
Final Random Inspection (FRI)
A last quality checkpoint performed on finished goods pulled randomly before shipment.
First Article Inspection (FAI)
A comprehensive verification of the first production run to confirm the process can produce parts that meet specifications.
First pass yield
The percentage of units that pass each process step without rework, repair, or retest.
FMEA (Failure Mode and Effects Analysis)
A risk assessment method for identifying potential failures, their causes, and their effects before production issues occur.
Gage R&R
A study that evaluates measurement system repeatability and reproducibility across operators and equipment.
Gemba walk
A structured visit to the production floor where leaders observe work, ask questions, and identify improvement opportunities.
Golden sample
A master-approved reference sample used to align quality expectations across buyers, suppliers, and inspectors.
In-Process Quality Control (IPQC)
Monitoring and verifying quality characteristics while production is underway.
Incoming Quality Control (IQC)
Inspection and verification of raw materials and components before they enter production.
Kaizen event
A focused, short-term improvement workshop that targets a specific process or quality challenge.
Layered process audit (LPA)
A structured audit system where leaders at different levels review critical process checkpoints on a rotating cadence.
LCL / UCL (Lower and Upper Control Limits)
The statistical boundaries on control charts that signal when a process may be shifting out of control.
Line clearance
A verification step ensuring production lines are free of previous materials, labels, and documents before starting a new order.
Measurement system analysis
A framework for validating that measurement tools, methods, and operators produce consistent and accurate data.
Nonconformance report (NCR)
Documentation that records a deviation from specified requirements and the actions taken to resolve it.
OTIF (On-Time In-Full)
A supply chain performance metric combining delivery punctuality with order completeness.
Outgoing quality control
Final verification process before goods leave the facility to confirm quality, packaging, and documentation readiness.
PPM (Parts Per Million)
A defect rate metric expressing how many units out of one million are non-conforming.
Pre-Production Inspection (PPI)
A quality assessment performed before mass production begins to validate materials, tooling, and process readiness.
Production Part Approval Process (PPAP)
A structured submission that proves a supplier can consistently meet customer engineering and quality requirements.
Quality gate
A mandatory control point where predefined criteria must be met before work can move to the next stage.
Quality Management System (QMS)
An organisational framework of policies, processes, and resources dedicated to achieving quality objectives.
Quarantine lot
A segregated batch of material or products held from normal flow until quality disposition is completed.
RCA (Root Cause Analysis)
A structured investigation method used to identify the underlying causes of a problem or defect.
Rework and repair
Actions taken to bring nonconforming product back to acceptable condition, either by restoring specification (rework) or making an approved fix (repair).
Risk Priority Number (RPN)
A score calculated by multiplying severity, occurrence, and detection ratings to prioritise risks in FMEA.
Sampling plan
A predefined method for determining how many units to inspect and the acceptance criteria used for lot disposition.
SOP (Standard Operating Procedure)
A documented instruction that defines how to perform a task consistently and safely.
Statistical Process Control (SPC)
A method of using statistical techniques to monitor and control processes by tracking variation over time.
Supplier Corrective Action Request (SCAR)
A formal request asking a supplier to investigate and resolve a quality issue that impacted delivered goods.
Supplier Quality Management (SQM)
The strategy and processes used to evaluate, monitor, and improve supplier performance.
Supplier scorecard
A performance framework used to evaluate suppliers across quality, delivery, responsiveness, and improvement metrics.
Traceability matrix
A document or system that links requirements to inspection steps, records, and approvals for full lineage tracking.
Visual inspection
A quality check method that relies on human observation to identify appearance defects and workmanship issues.
Workmanship standard
A documented set of visual and functional acceptance criteria that defines what is acceptable, marginal, or rejectable.
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