What a Quality Escape Actually Costs (And Why Most Shops Underestimate It)
A quality escape is more than the cost of the bad part. Here's what actually gets added up when a defect reaches a customer, and why most shops only count half of it.
You run dozens of part numbers with a small team and no IT department. ShopBoard scores SQDC on the cell, not the part. Scrap goes in by part number and dollars, so you see which parts cost the most.
Free forever: 1 department, 2 cells, 1 user · No card
Dozens of open jobs, each with its own cycle time. A target per part on the whiteboard is wrong by second shift.
The bin gets tallied on a sheet. Nobody knows which part cost the most until the books close.
The customer wants a root cause by Friday. The notes were on a whiteboard that got wiped Tuesday.
Per-seat pricing and a rollout project. It assumes an IT department you don't have.
A manager gives each cell its own shift times, Delivery Target % and Quality Target %. Each day's Quality and Delivery cards start at those targets. Type the actual % and the card turns green, yellow or red.
Hour-by-hour has no part field. Plan and Actual are whole numbers, so count pieces or kits. A supervisor saves a default plan for each hour. When the job changes mid-shift, they edit it and apply it again.
Each entry needs a cell and part number, plus quantity and unit cost. Pick the part from your list and the description and cost fill in. Vendor defects go in as Incoming, with a Return to Supplier disposition. The day's scrap dollars land in that cell's Cost square on their own.
The Pareto ranks your top 10 part numbers by scrap dollars. Filter it by cell or department. Click a reason in the table to see the parts behind it. A supervisor can start an A3 on a part from its row.
| Per cell | Per part number | |
|---|---|---|
| Quality and Delivery targets | Yes | No |
| Hour-by-hour plan and actual | Yes, whole-number counts | No |
| Scrap units and dollars | Yes, in the day's Cost square | Yes, on every scrap entry |
| Monthly report | Scrap $ for each cell | Top 5 parts by scrap value |
Part numbers live only on scrap entries and in your parts list.
Nothing to install and no server. Wall view puts a cell board on a floor TV from any computer with a browser.
CSV import comes with every plan, Free included. A manager loads cells, targets and past SQDC and hour-by-hour numbers. The Import tab previews each row and skips the bad ones. Your parts list loads on the Parts tab.
Free covers 1 department, 2 cells and 1 user, with every core module. Starter is $199 a month for 3 departments, 10 cells and 5 users. Professional is $499 a month for unlimited cells and users, plus the AI Lean Coach.
Log the complaint as a Quality issue. A supervisor works it as a 3C, then an A3 if the 3C doesn't hold. The A3 exports to PDF, or to PowerPoint with editable tables.
No. Targets live on the cell, and hour-by-hour has no part field. When a cell switches jobs, a supervisor edits the default hourly plan and applies it again.
No. There's no connector and no API. Export a CSV from your ERP and match our column headers. A manager loads it in Settings. On Enterprise, we map your exports to our imports with you.
Yes. A manager uploads a comma-separated file in Settings > Parts. The headers are part_number, part_description, standard_cost and unit_of_measure. Leave commas out of descriptions and $ signs out of costs. An existing part number gets updated, not duplicated.
Yes. Every cell counts, and cells can't be deleted. A manager can rename the sample cell and change its targets in Settings > Cells. Its sample history stays.
A quality escape is more than the cost of the bad part. Here's what actually gets added up when a defect reaches a customer, and why most shops only count half of it.
A3 has a reputation for being a big-company lean tool. Here's a stripped-down version that actually fits a smaller shop, without the jargon.
The six columns of a working hour-by-hour board template, what each is for, why cumulative gap beats the hourly number, and how to set plan when takt moves.
A sample board opens on your first login. Set up your own cell in about 10 minutes, then load your parts list.