Tool 60: Defect Map

AKA

Defect Location Checksheet, Concentration Diagram

Classification

Data Collecting (DC)

Tool description

A defect map displays the location of defects and simplifies the process of data collection and repair. Problem locations are marked so that repair staff know where to look.

Typical application

• To point to the location of defects or problems on rejected products.

• To mark or check off the locations of defects on an assembly diagram for the purpose of collecting frequency data of the various defects observed.

Problem-solving phase

→	Select and define problem or opportunity
→	Identify and analyze causes or potential change
	Develop and plan possible solutions or change
	Implement and evaluate solution or change
	Measure and report solution or change results
	Recognize and reward team efforts

Typically used by

	Research/statistics
	Creativity/innovation
4	Engineering
	Project management
1	Manufacturing
	Marketing/sales
3	Administration/documentation
	Servicing/support
2	Customer/quality metrics
	Change management

links to other tools

before

• Data Collection Strategy

• Checksheet

• Checklist

• Observation

• Quality Chart

after

• Pareto Chart

• Problem Specification

• Failure Mode Effect Analysis

• Potential Problem Analysis (PPA)

• Countermeasures Matrix

Notes and key points

• Use checksheets to record and summarize various defect map data.

Step-by-step procedure

• STEP 1 A defect map can be drawn for specific parts, assemblies, or complete units of product. Assembly drawings can also be used as defect maps. See example Sub-Assembly No. 314—Location of Defects.

• STEP 2 During inspection of parts, assemblies, or units, the observed location of defects is marked on defect maps.

• STEP 3 Defect types, locations, and frequencies are summarized on a checksheet as shown in the example.

• STEP 4 Use this type of historical defect data to prepare a problem specification statement.

• STEP 5 Provide notes on drawings, and date all documentation.

Example of tool application

Sub-Assembly No. 314—Location of Defects