From: Stan Hilliard
Date: 01 Apr 2000
Time: 23:05:17
You say that if your customer finds a defective piece in their production line, they require 100% screening of the remainder of the lot. For a lot size of 30,000, one defective piece is only 1/30,000 or 0.003 percent.
If they can catch the defects in production, why don't you arrange for them to return the defectives for credit and analyze them for prevention purposes. A FMEA (Failure Mode and Effects Analysis) is more likely to lead to improving future quality than to screen for defective pieces that can be caught more efficiently in production.
Sincerely, Stan Hilliard