What is defect leakage?

Defect leakage occurs when a manufactured product (integrated circuit, mechanical component, etc.) contains a defect that is not detected by the manufacturer's quality control process and is subsequently released to the customer. Defect leakage can have serious consequences, such as product recalls, customer dissatisfaction, and financial losses for the manufacturer.

There are a number of factors that can contribute to defect leakage, including:

* Inadequate testing: The manufacturer's quality control process may not be rigorous enough to detect all defects.

* Human error: Inspectors may make mistakes when inspecting products for defects.

* Counterfeit components: Some manufacturers may use counterfeit components in their products, which are often not subject to the same quality control standards as genuine components.

* Design flaws: Some products may have design flaws that make them more susceptible to defects.

Defect leakage can be minimized by implementing a rigorous quality control process, using trained inspectors, and avoiding the use of counterfeit components. Additionally, manufacturers can design their products to be less susceptible to defects.

Here are some specific examples of defect leakage:

* In 2010, Toyota recalled millions of vehicles due to a defect in the accelerator pedal that could cause the car to accelerate unintendedly.

* In 2015, Samsung recalled millions of Galaxy Note 7 smartphones due to a defect that could cause the phone to catch fire.

* In 2017, Equifax, a credit reporting agency, experienced a data breach that exposed the personal information of millions of customers.

Defect leakage can be a serious problem for manufacturers, but it can be minimized by implementing rigorous quality control processes and using trained inspectors.