Defects are defined as any product that is unacceptable to the customer.
 Handling and transformation defects are considered. It is also defined as any rework or corrective action in addition to the work required to meet the customer expectation - the total waste from defective or rejected work includes the value of the work plus the opportunity lost by not doing the work correctly the first time.

Causes for defects:

Ø  Too many product models
Ø High inventory levels
Ø Inadequate tools/ equipment
Ø Poor employee training
Ø Poor layouts/ Unnecessary handling (Transport damage)
Ø Poor process documentation
Ø Processes which cannot consistently produce the Quantity  Or Quality required
Ø Irregular feed & speed of machines
Ø Non-Standard quality assurance and control

Solution for this waste:

Ø Prevention prior to detection
Ø Quality at source – online quality
Ø Chain of Quality/House of Quality
Ø Use of Andon must be encouraged
     Ã˜  Automation

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