In-line inspection is meant to protect quality. But for many precision component manufacturers, it’s doing the opposite, causing rework, missed takt times, and invisible cost leaks.
Here are five clear reasons why your inspection setup might be eating into profits — and what to fix.
1. Over-Reliance on Manual Gauges
Manual gauges introduce hidden costs:
- Measurement variation across shifts
- Calibration drift
- No traceability
- Unsuitable for tight tolerances or complex parts
The result: unreliable data, rework, and missed defects. Automated gauging systems offer consistency, eliminate operator dependency, and enable traceable inspection.
2. Inspection Slower Than Takt Time
If inspection takes longer than production, you’re losing time and money.
- Parts pile up waiting for clearance
- Delays in identifying defects
- Increased WIP and floor congestion
Inline or near-line inspection enables checks to run at production pace. Faster feedback means quicker correction and smoother flow.
3. Multiple Setups for One Component
When one part needs multiple setups or gauges:
- Inspection time increases
- Errors multiply during part handling
- Operator dependence rises
Multi-feature gauging systems allow complete dimensional checks in one cycle, saving time, reducing errors, and standardizing quality.
4. No Real-Time Feedback to Production
Delayed inspection means defects keep moving forward.
- No opportunity for in-cycle correction
- High scrap accumulation
- Longer root cause analysis
Real-time data enables quick adjustments. Closed-loop feedback loops tighten control and reduce quality loss.
5. Disconnected SPC and Inspection Systems
When inspection results aren’t linked to SPC:
- There’s no early warning for variation
- Trends are missed
- Analysis becomes post-mortem
Integrated SPC allows live monitoring, alerts, and preventive action keeping quality within limits before failure happens.
