Pattern Tracking Case
The Same Surface Pattern Appeared Across the Batch
A recurring visual signature appeared across multiple units, supporting a process-level root cause rather than random sample noise.
Open Case StudyVisual Metric
Ra 3.2–6.8μm
Observed roughness band across approved parts.
Acceptance Band
ΔGloss ≤ 12%
Surface variance accepted when function remains stable.
Escalation Rule
2+ Zones Match
Repeat in multiple locations flags process-level issue.
Visible Consistency Acceptance Bands
Green Band: Surface differences are noticeable but stable and documented; no functional change.
Amber Band: Visual shift increasing across sequence; add confirmatory sample before handoff.
Red Band: Surface anomalies align with dimensional or fit drift; pause and investigate process settings.
Surface Review Notes for Handoff
- Capture lighting setup used for visual comparison photos.
- Include roughness/gloss ranges, not only pass/fail tags.
- Separate cosmetic variance from functional conformity.
- Document whether the pattern was recurring or isolated.