In OEE (Overall Equipment Effectiveness), Quality is the most expensive loss.
When a machine breaks (Availability Loss), you lose time. But when a machine produces Scrap (Quality Loss), you lose time, energy, labor, and raw materials. It is a triple penalty.
Yet, most factories manage scrap with a "Tally Sheet" on a clipboard. The operator marks a line for every bad part and hands it in at the end of the day. By then, the materials are in the dumpster, and the root cause is lost.
To attack Quality Loss, you need Scrap & Defect Tracking Software that captures the failure in real-time. Here are the top 5 tools for 2026.
1. Fabrico (Best for Vision & Process Context)
The Verdict: The system that links "Defects" to "Machine Health."
Fabrico takes the top spot because it understands that Scrap is usually a symptom of a machine or process failure.
Why it wins for Scrap Tracking:
-
Computer Vision Detection: Fabrico can integrate with cameras to detect visible defects (e.g., missing labels, crushed boxes) automatically. It logs the scrap count without the operator touching a button.
-
Process Context: When a defect is logged, Fabrico captures the Machine Parameters from that exact moment (e.g., "Molder was running at 450°F"). This allows you to correlate Defects with Process Drift.
-
Digital Scrap Counters: For manual logging, operators use a simple "One-Tap" interface on a tablet. It calculates the financial cost of that scrap instantly, gamifying the reduction.
-
The Fabrico Agent: The AI analyzes trends. Example: "Scrap Rate increases by 5% every time Line Speed exceeds 300 ppm." It suggests the optimal speed to maximize yield.
Best For: High-speed manufacturing where process parameters drive quality.
2. SafetyChain (Best for SPC & Compliance)
The Verdict: The Quality Manager's toolkit.
SafetyChain is a heavyweight Quality Management System (QMS) with strong OEE capabilities.
Why it’s a contender:
-
SPC (Statistical Process Control): It excels at X-Bar and R-Charts. If you need to monitor weight control in food processing to prevent "Giveaway," this is the standard.
-
Compliance: Deep integration with GFSI/SQF requirements.
The Downside:
It focuses on "Compliance" (Pass/Fail) more than "Root Cause." It tells you the part failed, but it doesn't link that failure to the machine's maintenance history as fluidly as Fabrico.
Best For: Food & Beverage plants focused on weight/volume compliance.
3. Tulip (Best for Manual Defect Logging)
The Verdict: The custom app builder.
Tulip allows engineers to build visual "Defect Reporting" apps for manual inspection stations.
Why it’s a contender:
-
Visual Selectors: You can upload a photo of your product, and operators can tap the specific area where the defect is (e.g., "Scratch on Top Left Corner"). This creates a heat map of defects.
-
IoT Integration: Connects to digital calipers and scales for automated data entry.
The Downside:
You have to build the app yourself. It requires setup time to define every defect type and image.
Best For: Manual assembly and visual inspection stations.
4. InfinityQS (Enact) (Best for Statistical Analysis)
The Verdict: The data scientist's choice.
InfinityQS is a pure-play Statistical Process Control (SPC) platform.
Why it’s a contender:
The Downside:
It is a "Quality Lab" tool. It doesn't connect to the maintenance department. If the SPC chart goes out of control due to a loose bearing, InfinityQS won't generate the work order to fix the bearing.
Best For: Enterprise Quality Directors analyzing global trends.
5. QAD Redzone (Best for Team Engagement)
The Verdict: The culture of quality.
Redzone uses its "Huddle" philosophy to attack scrap.
Why it’s a contender:
-
Quality Huddles: It visualizes scrap data on big screens to drive team competition. "Shift A had 99.5% Yield; Shift B had 98%."
-
Operator Checks: Good for scheduling periodic quality checks (e.g., "Check weight every 30 mins").
The Downside:
It relies on human input and behavior. It lacks the Computer Vision / Automated Detection capabilities of more technical platforms.
Best For: Plants where operator inattention is the primary cause of scrap.
The Critical Feature: "The Financial Overlay"
Operators often ignore scrap because they see it as "just a bad part."
Fabrico changes behavior by showing the Financial Impact.
Instead of displaying "50 Rejects," Fabrico displays "-$450 Lost Material."
When the operator sees the dollar sign ticking up on the dashboard, the urgency to stop the machine and fix the root cause increases immediately.
Stop counting waste. Start preventing it. [See Fabrico's Scrap Tracking Features].
Login
Blog
