Production Updates
PU-001
Batch Seven Moved to Finishing Four Days Late
Held at inspection, released without rework
Stage
Released
Batch seven sat at inspection for four days over a seam tolerance that turned out to be measured against the wrong reference. Nothing was reworked; the reference was corrected.
What Held
Inspection flagged the shoulder seam on the whole batch. The tolerance it was checked against came from an earlier fit, and nobody had updated the sheet when the fit changed.
What Was Decided
Two options were on the table: rework the batch to match the old sheet, or verify the sheet against the current pattern and release the batch as made. The second was slower to decide and faster to finish.
Reworking would have destroyed four days of correct work to satisfy a document that was itself wrong.
Batch Log
| Day | Stage | Note |
|---|---|---|
| 1 | Cutting | Complete, no flags |
| 2 | Assembly | Complete |
| 3 | Inspection | Held — shoulder seam flagged |
| 4-6 | Inspection | Reference sheet checked against current pattern |
| 7 | Inspection | Released, sheet corrected |
| 8 | Finishing | Moved, four days behind schedule |
What Changed Afterwards
The tolerance sheet is now versioned with the pattern rather than kept beside it. A document that can drift away from the thing it describes will eventually do so.
A delay caused by checking is a different kind of delay from one caused by error, and a production log that does not distinguish them teaches the floor to stop checking.
Batch
- Batch
- Seven.
- Quantity
- Full run, none pulled.
- Held at
- Inspection, four days.
- Reworked
- None.
- Outcome
- Released as made; reference corrected.