Defect Classification

IPC-7912A standard defines defect classification for the four main categories: Component (C), Placement (P), Termination (T) and Assembly (A). Even though you do not want to use complete IPC-classification, this list can help you to map your own defect groups to C-P-T-A -categories. You can of course classify your defect different from IPC -classification but your DPMO figures are not comparable with other production lines.

Component Defects
Base material damage
Bent lead
Birdcaged wire
Blisters, mealing, peeling
Board warped or bowed
Cable made wrong
Circuitry damaged
Connector damaged
Gold not removed
Improper stress relief
Incorrect terminal flange
Insulation clearance wrong
Insulation or wire conductor damage
Lead bent problem
Lead coplanarity out of spec
Lead forming wrong
Lead/cable length wrong
Leads bent under
Leads not tinned
Marking/labeling incorrect
Part damaged
Part lead stressed
Plating or other part finish problem
Sleeving problem
Solderability problem
Spliced where not permitted
Unprepped part
Wire damage
Wire not tinned when required
Placement Defects
Cable connected wrong
Component/Parts/Hardware loose/missing/wrong
Crimping wrong
Improper mounting
Lead/cable routing wrong
Min. elect clearance violated
Part height wrong
Part misaligned
Part, extra
Part, mounted wrong
Tilted part
Wire connected wrong
Wire routing wrong
Termination Defects
Blow holes
Cold solder joint
Disturbed solder joint
Fractured solder joint
Insufficient solder
Lead protrusion wrong
Part coating meniscus in joint
Solder bridge
Solder wetting unacceptable
Unsoldered connection
Assembly Defects
Assembly not clean
Conformal coating not present where required
Conformal coating peeling
Conformal coating present where not wanted
Solder balls/splash