In our previous article, we talked about the Acceptance Quality Limit and three different types of defects which can be found in your products: critical, major, and minor. But how to classify these defects and which of them occur the most in different types of products? Over the last years, GQC team of inspectors has visited hundreds of factories for quality control of different products. Although each product is unique, we were able to classify our observations by general industry.
As we mentioned before, quality control professionals typically classify quality defects into three main categories: minor, major, and critical. The nature and severity of a defect determine which of the three categories it belongs to. Let’s look at each of these defect types and examples from different industries.
Minor Defects
If a defect is classified as minor, that means the item does not comply fully with the product specs but is still usable. The defect does not affect the product’s marketability and functionality and only has minimal issues with its appearance. A minor defect is typically insignificant, so the end-users might not even notice it. And even if they do, they are not likely to return the item, request a refund, or decide against buying it.
Some common minor defects:
Untrimmed threads – these are a common quality issue in garment manufacturing. Factories can easily rework this defect by simply cutting the excess threads. But it is up to the buyer to classify this defect as minor or major. If you are selling higher-end garments, you and your retailer might not tolerate even such small imperfections and classify them as major defects.
Scratches and surface defects – small scratches or abrasions on the surface of a hardline item could be related to a quality defects production process or simply rough handling. These damages on the surface of an item typically won’t hurt the product’s salability and can be classified as a minor defect.
Major Defects
Major defects are considered much more serious than minor ones. Not only do major defects cause your product to depart significantly from the buyer’s specs, but they could also negatively impact the appearance, performance, or function of the defective item. Additionally, end-users are highly likely to notice major defects and return the item or ask for a refund.
Some common major defects:
Going back to softlines manufacturing. Missing stitches – these typically appear due to a fault with the sewing machine or an operator error. Missing stitches impact the product's visual appearance and can even affect its functionality, making this a more serious quality issue.
For electronics manufacturing, any issues related to the product’s performance can be classified as major. Malfunction issues with an electronic product might include a failure to turn on, display issues, or poor connectivity. Typically, the manufacturer has to rework these products.
Critical Defects
Critical defects are the most serious defect type and typically mean that the product is completely unusable. Items with critical defects can also be a health and safety hazard to your customers or anyone who will use them. And if your goods are a risk to people’s health, that means you are at risk of potential lawsuits and product recalls, which can poorly affect your reputation as a brand.
Some common critical defects:
Any sharp items which can scratch or prickle the end-user. It includes all defects concerning safety, such as pins, needles, and staples that were not removed. This quality issue is almost always classified as a critical defect and can result in the item failing inspection.
As for electronics, one of the most dangerous defects is damaged wiring. Damaged or exposed wiring (failed Hi-Pot or Earth test) is always classified as a critical defect. Compromised wiring is clear health, safety, and fire hazard with potentially fatal consequences such as electric shock and electrocution.
These are rough guidelines QC professionals typically follow for defect classification. It is a vital step in the inspection process. A well-thought-out defect categorization can greatly improve quality control, cut down your losses, and boost customer satisfaction. But as the buyer, always consider the severity of different defect types and their effect on your customers and brand when setting tolerances. If you have more questions or would like to receive a sample QC report, please contact our team to book a free consultation.
