Post at every scrap point — one card per machine or cell | sharpenmfg.com
| Code | Name | Definition | Example |
|---|---|---|---|
| 01 | Process Variation | Part rejected due to process drift or instability during a run | Dimension creeping toward the reject limit across 50 consecutive parts |
| 02 | Tooling Failure | Part defective due to broken, worn, or improperly seated tooling | Punch cracked mid-run; burr on all parts from that die position |
| 03 | Setup Error | Part defective due to incorrect machine setup, offset, or fixturing before the run | Wrong offset entered; first 8 parts out of tolerance before caught at first-off |
| 04 | Incoming Material | Defect caused by dimensional, chemical, or surface variation in the input material | New coil lot thicker than spec; blanks exceed upper tolerance |
| 05 | Handling Damage | Part damaged after production, during movement between operations or to storage | Scratch introduced in transit tote; dent from conveyor transfer |
| 06 | First-Off Reject | Part rejected during first-off inspection before the run is approved to continue | Setup required two attempts; first part scrapped per procedure |
| 07 | Rework Converted | Part originally logged as rework but downgraded to scrap after rework failed or exceeded cost threshold | Weld repair cracked on reinspection; part scrapped |
| 08 | Operator Error | Catch-all for defects attributable to operator action not covered by other codes; retire as specific patterns emerge | Part loaded in wrong orientation; marked surface scratched during handling |
| 09 | Other | The cause cannot be confidently classified into any existing code, whether unknown or not yet categorized | Novel defect from new tooling not yet categorized; cause under investigation |