Defect Counter

How the Defect Counter Works

The Defect Counter tallies defects by category, such as scratch, dent and misprint, and calculates the defect rate against units inspected. One button per defect type keeps categories separate.

1. Create defect categories: Add buttons for each defect type you track.
2. Count inspected units: Tap Inspected for every unit checked.
3. Tap defects found: Tap the matching category for each defect found.
4. Read the Pareto list: The tool sorts categories from most to least frequent.

Defect Counter Formula

The Defect Counter defect rate equals defects divided by units inspected, and defects per million opportunities (DPMO) scales that rate to 1 million.

Defects

Defects found

Units

Units inspected

Opportunities

Possible defect types per unit

Example: Inspectors check 1,200 units with 5 defect opportunities each and find 18 defects. Defect rate = 1.5%. DPMO = 18 ÷ 6,000 × 1,000,000 = 3,000.

Defect Counter Reference Table

The Defect Counter conversion table converts DPMO into yield and Six Sigma level.

About the Defect Counter

A Defect Counter is a quality tool that tallies defects by type during inspection. Categorized counts show which problems to fix first.

Quality teams sort defect counts into a Pareto chart. The Pareto principle states that roughly 80% of defects come from 20% of causes, so the top 1 or 2 categories usually deserve attention first.

Ways to Use the Defect Counter

The Defect Counter has 5 main uses, including incoming inspection and Pareto analysis.

• ✓Incoming inspection: Teams count supplier defects on delivered parts.
• ✓Pareto analysis: Engineers rank defect types to target fixes.
• ✓Final inspection: Inspectors log defects before shipping.
• ✓Print checks: Print shops count misprints by type.
• ✓Garment checks: Sewing teams count stitching faults by category.