Inspection is where a forge finds out what the furnace and the press did. A pass/fail count tells you how much you lost; it does not tell you that this month’s laps are the same laps, on the same die, that appeared last month. Repeat defects are the cheapest thing in a forge to fix and the hardest to see.
Your ERP records the result: passed, rejected, quantity.
It won’t tell you this is the third month running for the same lap on the same die.
Why the gap existsWhere the losses hide
A reject rate is a total. A defect family is a cause — and causes are what you can actually act on.
Laps, folds, cracks and decarburisation each trace to a different stage — the die, the heat, the soak. Counted together as rejects, they average into a number that points nowhere.
A forging failed on magnetic particle came from a specific die and a specific billet heat. Without that trace, the finding stops at the inspection bench.
A return is recorded as a return. Connecting it back to the die and cycle that produced the part is the difference between a credit note and a fix.
The join
Same run, same clock, same asset — three streams that only mean something together.
Inspection outcome, quantity passed and rejected, disposition.
The defect tagged by family at the bench, against the die, billet heat and batch it came from — and NDT results tied to the same record.
Rejects grouped by defect family and traced back to the die or heat that produced them, instead of a monthly percentage.
What Munshi surfaces
Teal is normal, maroon is flagged. Illustrative data.
Tagged at the bench by family, not lumped into a single reject count.
A number that is not improving is a cause that has not been found.
When an outcome moves and a signal moves with it, Munshi shows both and says they moved together. It does not tell you one caused the other. The operator confirms the cause, and the confirmed cause is written back to that asset’s register — so the pattern is already named the next time it appears.
Related stages
Descaling that quietly uses more media as the wheel wears.
Manipulators, hydraulic packs, compressors and utilities.
Get started
See this on your own line.
Bring a month you already understand. The useful test is whether Munshi finds what you already know — and then what you didn’t.