Deutsch: Ausschuss / Español: Desecho / Português: Refugo / Français: Rebuts / Italiano: Scarto
Scrap in quality management refers to defective or unusable materials, components, or products that do not meet quality standards and cannot be reworked or repaired. These items are discarded, often leading to financial losses and waste. Effective quality management aims to minimise scrap through improved processes, preventive measures, and defect reduction strategies.
Description
Scrap is a significant concern in manufacturing, production, and service industries, as it represents wasted resources, time, and costs. Scrap can result from various factors, including:
- Defective raw materials – Poor-quality inputs leading to unusable finished products.
- Production errors – Mistakes in machining, assembly, or processing.
- Machine malfunctions – Equipment failures causing incorrect or damaged products.
- Human errors – Mistakes in handling, measurement, or assembly.
- Design flaws – Poor product design leading to manufacturing defects.
To manage scrap effectively, businesses implement Lean Manufacturing, Six Sigma, and Total Quality Management (TQM) strategies. These methodologies focus on root cause analysis, continuous improvement, and process optimization to reduce waste and enhance efficiency.
Special Considerations
A Scrap Reduction Program can help organisations track, analyse, and minimise scrap generation. Key strategies include:
- Improving supplier quality – Ensuring high-quality raw materials.
- Enhancing employee training – Reducing human errors through proper instruction.
- Process automation – Using technology to improve precision and consistency.
- Implementing Statistical Process Control (SPC) – Monitoring production data to detect and prevent defects.
Application Areas
- Manufacturing: Defective parts, damaged components, or failed assemblies.
- Automotive Industry: Faulty engine parts, rejected body panels, and misaligned components.
- Electronics: Malfunctioning circuit boards, incorrect soldering, and broken chips.
- Textile Industry: Wasted fabric due to misprints, dyeing errors, or improper cutting.
- Construction: Incorrectly measured materials, broken tiles, or faulty concrete batches.
Well-Known Examples
- Toyota’s Lean Manufacturing System: Minimises scrap by focusing on continuous improvement.
- Intel’s Semiconductor Production: Uses precision control to reduce chip defects.
- Airbus & Boeing: Reduce material waste through precision engineering and supplier quality control.
- Textile Recycling Initiatives: Companies repurpose scrap fabric into new products to reduce waste.
Risks and Challenges
- High production costs: Increased expenses due to wasted materials and rework.
- Environmental impact: Excessive waste contributing to sustainability concerns.
- Supply chain inefficiencies: Scrap from poor supplier quality affecting production flow.
- Customer dissatisfaction: Defective products increasing returns and complaints.
Similar Terms
- Rework – Defective products that can be corrected instead of being discarded.
- Waste – General term for unusable materials, including scrap and by-products.
- Defects – Flaws in products that may lead to scrap or rework.
- Yield loss – The percentage of products lost due to quality issues.
Summary
Scrap in quality management represents wasted materials, products, and resources that do not meet quality standards. It impacts costs, efficiency, and sustainability, making scrap reduction a key goal in quality improvement initiatives. By implementing process optimization, automation, and supplier quality control, organisations can significantly reduce scrap and improve overall operational efficiency.
--