Meaning
Automated decision points use predefined probability limits to accept or reject parts moving through a production sequence. Effective statistical gating prevents defective units from consuming expensive downstream processing time. This logic is built into the control software to ensure that only parts with a high probability of being good continue through the line.
Rejection Logic
Comparison between the measured values and the statistical limits determines the fate of each unit. If a part falls into the tail of the distribution, it is automatically diverted to a rework station.
Throughput Control
Setting the gates too tightly can lead to a high rate of false rejections, which reduces the total yield of the factory. Managers must find the balance where the cost of a false rejection is lower than the cost of allowing a defect to reach the customer. This decision is based on the demonstrated capability of the machines and the risk profile of the product.
The gates can be adjusted in real time as the process stability improves or degrades.
Risk Mitigation
Using multiple gating stations throughout the line helps catch errors early in the manufacturing process. This reduces the total energy and material wasted on faulty components.