Inspection is where a foundry finds out what the previous six stages did. A pass/fail count tells you how much you lost; it does not tell you that four of this month’s rejects are the same defect on the same pattern that appeared last month. Repeat defects are the cheapest thing in a foundry to fix and the hardest to see.
Your ERP records the result: passed, rejected, quantity.
It won’t tell you this is the fourth month running for the same defect on the same pattern.
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.
Blow holes, shrinkage, inclusions and dimensional faults each trace to a different stage. Counted together as "rejects", they average into a number that points nowhere.
A casting rejected at final inspection came from a specific heat, a specific mould and a specific pour. Without that trace, the finding stops at the inspection bench.
A return is recorded as a return. Connecting it back to the conditions 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 heat, pattern and batch it came from - and NDT or spectro results tied to the same record.
Rejects grouped by defect family and traced back to the stage 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
Energy per batch, cycle deviation and re-treat loops.
Cranes, pumps, compressors, cooling and extraction.
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.