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The sampling standard used is ANZI/ASQ Z1.4-2008.In the case of product #2 our incoming inspection plan calls for a sample size of 32 out of lot size of 1,000. The lot acceptance is AQL 1.0 which equates to acceptance of the lot at 1 defector reject entire lot at 2 defects. Since I reached the 2nd defect at 12 samples I stopped as the lot was already disqualified. The loss of bonding to the metal indicates a process issue that would affect the entire production and we would be remiss to assume that the rest of the lot is affected. We need a root cause analysis to determine how wide spread the issue is and of course a countermeasure to prevent recurrence.
The product#1 inspection was prompted by a customer complaint. This is a medical customer and the expectation is for a cosmetically pleasing part as it is used in a sanitized environment. The sampling size was 200 with an AQL of 4.0 and lot reject criteria of 15. I exceeded this criteria of 15 even further as I found additional issues with flash and trimming.
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