# Critical, Major and Minor Defect Classification List > Source: https://netray.co/tools/visual-defect-severity-classification-reference > Publisher: Netray (netray.co), AI and integration engineering for ERP and manufacturing systems. > Section: Free Tools ## Short answer Starting list of common inspection defects with a suggested severity class and why, to speed up writing your own defect classification procedure. ## Category quality ## Audience - Quality inspector - Receiving inspector - Quality engineer ## Tool **Kind:** worksheet **Mode:** reference **Columns:** #### Defect **Key:** defect **Type:** text #### Area **Key:** area **Type:** text #### Suggested class **Key:** cls **Type:** text #### Rationale **Key:** why **Type:** text **Rows:** **Defect:** Crack in load bearing weld or casting **Area:** Structure **Cls:** Critical **Why:** Can cause failure and injury **Defect:** Missing safety guard or interlock **Area:** Assembly **Cls:** Critical **Why:** Hazard to the end user **Defect:** Wrong part or wrong material grade **Area:** Identification **Cls:** Critical **Why:** Fit or safety function cannot be assured **Defect:** Exposed live conductor **Area:** Electrical **Cls:** Critical **Why:** Shock or fire risk **Defect:** Missing required label or warning **Area:** Labeling **Cls:** Critical **Why:** Regulatory or safety requirement **Defect:** Critical dimension out of tolerance **Area:** Dimensional **Cls:** Major **Why:** Fit or function affected **Defect:** Missing fastener **Area:** Assembly **Cls:** Major **Why:** Function or durability affected **Defect:** Burr on a mating or sealing surface **Area:** Machining **Cls:** Major **Why:** Leak or wear risk **Defect:** Cold solder joint **Area:** Electronics **Cls:** Major **Why:** Intermittent failure **Defect:** Insufficient plating thickness **Area:** Finish **Cls:** Major **Why:** Corrosion protection reduced **Defect:** Incorrect torque or unverified torque **Area:** Assembly **Cls:** Major **Why:** Joint integrity at risk **Defect:** Packaging damage exposing the product **Area:** Packaging **Cls:** Major **Why:** Product damage in transit **Defect:** Scratch on a non functional cosmetic surface **Area:** Cosmetic **Cls:** Minor **Why:** Appearance only **Defect:** Slight color variation within sample range **Area:** Cosmetic **Cls:** Minor **Why:** Appearance only **Defect:** Burr on a non critical edge **Area:** Machining **Cls:** Minor **Why:** Handling or appearance only **Defect:** Minor label misalignment **Area:** Labeling **Cls:** Minor **Why:** Content legible and correct **Defect:** Loose threads or trim on soft goods **Area:** Textile **Cls:** Minor **Why:** Appearance only **Defect:** Carton dent without product damage **Area:** Packaging **Cls:** Minor **Why:** No functional effect **Notes:** These classes are suggestions. Your customer, drawing, workmanship standard or quality agreement defines the final classification and may treat any of these differently. Document the agreed list in the inspection procedure. ## Content **Intro:** Sampling plans such as ANSI Z1.4 need defects sorted into classes, and each class often has its own AQL. This list gives a practical starting point for critical, major and minor examples that you can adapt. **Sections:** #### How to use the list **Body:** Search for the defect you see or the area you inspect. Treat the suggested class as a draft and agree it with your customer or supplier. Then copy the agreed rows into your inspection instruction so every inspector classifies the same way. Export the table to Excel and add a column with a photo reference or limit sample ID for borderline cases. #### What the three classes mean **Body:** A critical defect is one likely to cause harm or violate a regulation. A major defect is likely to result in failure or materially reduce usability. A minor defect departs from the standard but is unlikely to affect use. Common practice is zero tolerance for critical, a tighter AQL for major, and a looser AQL for minor, but the numbers come from your contract or internal policy, not from this list. **Bullets:** - Critical: safety, legal or regulatory impact - Major: function, fit or durability impact - Minor: appearance or small departure - Agree the class before the first inspection #### Common mistakes **Body:** Leaving classification to the individual inspector produces unstable results between shifts and sites. Another mistake is calling everything major so that the AQL becomes unreachable, which leads to ignored rejections. Use limit samples and photographs, review the list after every customer complaint, and set the defect code in your ERP so Pareto reports use the same categories. **Cta:** If defect codes differ across plants, Netray can help standardise them and report on defects by class in your ERP. **Faq:** #### Who decides whether a defect is critical, major or minor? **Answer:** The customer specification, drawing or quality agreement decides. Where none exists, the manufacturer's quality procedure defines classes, ideally agreed with the customer before the first lot is inspected. #### Should critical defects have an AQL? **Answer:** Many organisations use zero tolerance for critical defects, meaning any occurrence is a rejection and often triggers 100 percent screening. Some contracts still state an AQL such as 0.065 for criticals. Follow your contract. #### How many defect classes should I use? **Answer:** Three is the common choice because it matches how sampling standards and consumer goods audits describe defects. Aerospace and automotive customers often prefer a defect code list tied to characteristics instead of classes. #### Can one defect have different classes in different products? **Answer:** Yes. A scratch is cosmetic on a housing but major on a sealing surface. Classify by effect on the specific part, not by the defect name alone. ## Search terms critical major minor defect examples, defect classification list, defect severity classification, visual inspection defect list, AQL critical major minor definitions, inspection defect categories, quality inspection defect examples, defect classification for AQL --- Talk to an engineer: https://netray.co/contact?intent=erp_ai | Machine catalog: https://netray.co/agent/catalog.json