If you don't care for the term "operator error", you really wouldn't enjoy "unknown".
We used it when there was no way to pin down the cause. Talking with all personnel in the loop, no legitimate cause could be determined. We had 15/18 operations where nicks and scratches could have ocurred. Nobody in the process could point to the cause. We used "unknown", with separating the parts with dividers to eliminate normal handling. That's alot more honest then blaming an Operator. If it's Operator Error, that's the cause. With 40 operators, and not always the same one responsible, it's hard to believe it's a training issue. You can say it, but that don't make it so. It also has to be mentioned that the company's PPM defects didn't even show on the customers' quarterly report. So the customer had to change to report to show units on the graph to a max of 10. Then we can see 5 pcs rejected out of thousands shipped. Think about it. 1500 pc order with one pc having blurred part marking. Another 2000 pc order with a scratch on it. This with an approved sampling plan for final inspection. The amount of time required and the futility of determining who, what and where, just doesn't "add value". Most importantly, the orders kept coming. It's not a perfect world and some customers that know you provide superior product are aware of it. Once more, Customers that demand full blown investigations in light of the conditions I mentioned, employ way too many Quality Geeks with not enough work to do. They are just feathering their nests and beating their inflated chests because as the Customer, they can. I want to add that the average cost per part is about $2 or $3 each, with the customer continuously trying to nickel and dime that cost down. Some parts aren't even a $1. Give me a break!
[This message has been edited by energy (edited 08 May 2001).]