What is your processing procedure when products fail inspection?

Question

Accepted Answer

Rika always takes zero defect and high reliability as the quality goal. For the full range of environmental sensor products, we have established and strictly implemented a standardized and traceable non-conforming product control procedure to ensure that any unqualified products will not flow into the next process or be delivered to customers, while solving problems at the root to avoid recurrence. The specific procedure is as follows:

Strict Identification & Segregation

Upon detection of any parameter deviation , our QC team immediately moves the affected units to a controlled "Red Zone." They are labeled with high-visibility tags to physically prevent them from entering the finished goods inventory or the weather station assembly line.

Root Cause Analysis (RCA)

The Quality Assurance (QA) department leads a cross-functional review involving R&D, engineering, and procurement. Using methodologies like Fishbone diagrams or "5 Whys," we determine if the failure stemmed from raw material inconsistencies, manufacturing deviations, or environmental stress.

Classified Disposition

Based on the RCA report, a disposition decision is made:

Rework/Repair: If the unit can be restored via recalibration or modular replacement, it undergoes rigorous specialized testing post-repair.
Scrap: If there is damage to the core sensing element or irreparable structural flaws, the unit is mandatorily scrapped to ensure no compromised hardware reaches the client.

Comprehensive Re-inspection

Reworked products are not just re-tested for the failed parameter; they must undergo the entire "Final Quality Control (FQC)" sequence again to guarantee that the repair process hasn't impacted overall performance.

CAPA & Continuous Improvement

Every non-conformance is logged into our quality database, triggering Corrective and Preventive Actions (CAPA). This may involve upgrading production jigs, optimizing calibration algorithms, or tightening supplier entry standards to prevent recurrence from the source.