Monthly Apparel Quality Control Defect Analysis Report

Comprehensive analysis of product quality metrics across manufacturing and inspection processes, focusing on defect rates, types, and trends to maintain product excellence and minimize waste.

Report Objective

Track and analyze quality control metrics across our apparel manufacturing process, identifying defect patterns, evaluating inspection effectiveness, and recommending process improvements to maintain high quality standards while minimizing waste and rework costs.

Defect Rate Analysis

Line chart showing defect rates by product category and severity levels

Questions to Consider:

2024-032024-042024-05inspection_date200.0%220.0%240.0%sum(defect_rate) vs. product_categorysum(defect_rate)product_categoryHow are Monthly Defect Rates Trending by Product Category?Defect rates show variation across product categories with seasonal patterns

  • Which product categories show the highest defect rates?

  • Are there consistent seasonal patterns in defect rates?

  • How do current rates compare to previous months?

  • Which product categories consistently maintain lower defect rates?

  • How do defect rates vary between product complexity levels?

  • Are there specific categories requiring immediate attention?

Womens_WearMens_WearChildrens_WearAccessoriesFootwearproduct_category0.0%1000.0%2000.0%3000.0%4000.0%sum(defect_rate)sum(defect_rate)Product Categories by Average Monthly Defect RateComparative analysis of quality performance across product lines

Quality Control Efficiency

Bar charts comparing inspection points and defect detection rates

Questions to Consider:

CuttingSewingFinishingPackagingTestinginspection_point0%50000%100000%150000%sum(detection_rate)sum(detection_rate)Defect Detection Effectiveness by Inspection PointAnalysis of quality control checkpoint performance

  • Which inspection points are most effective at catching defects?

  • Are there inspection points requiring process improvement?

  • How does detection effectiveness vary by inspection stage?

  • Which stages catch the most defects?

  • Is the distribution of defects appropriate for each stage?

  • Are early-stage inspections effective at preventing downstream issues?

CuttingSewingFinishingPackagingTestinginspection_point01,0002,0003,0004,000sum(defects_found)sum(defects_found)Monthly Defects Found by Inspection PointDistribution of defect detection across quality control stages

Root Cause Analysis

Detailed breakdown of defect types and their sources

Questions to Consider:

Stitching_ErrorFabric_FlawColor_VariationWrong_Sizedefect_type05001,0001,5002,000sum(occurrence_count)CriticalMajorMinorDistribution of Defect Types by SeverityAnalysis of defect patterns and their impact on quality

  • What are the most frequent types of defects?

  • How are critical defects distributed across defect types?

  • Which defect types should be prioritized for process improvement?