Undetected Defects in Optical Quality Inspection Leading to Rework and Waste

$100,000-$350,000 annually from defective glass (assembly rework labor not fully charged to supplier, scrap losses absorbed in production variance, delayed supplier credits, margin erosion) • $100,000-$400,000 annually from defective glass (assembly rework labor, field warranty claims, reduced panel performance claims, margin compression, potential litigation if defects cause field failures) • $100,000-$400,000 annually from defective glass (rework labor, regulatory investigation costs, inventory write-offs, expedited replacement supply, potential compliance penalties if defects reach market)

Assembly rework hours tracked by defect type in production log or spreadsheet; warranty claims logged in CRM or email; correlation between batch and warranty claims made manually by Quality Engineer; cost impact quantified post-hoc in Excel; supplier performance tracked informally • Assembly rework labor hours logged against generic rework GL account; scrap glass tracked by weight in inventory system; supplier credit memos matched manually to purchase orders; defect root cause not captured in accounting; quarterly supplier performance review based on visual inspection logs and email claims • Incoming inspection using visual standards and measurement calipers; defect photos emailed to supplier; batch quarantine spreadsheet; manual rework scheduling; field failure complaints tracked in CRM or email chains; warranty claims processed manually