The Latent Quality Risk

The Latent Quality Risk introduces a quantitative framework for understanding quality risk that may remain hidden after conventional inspection and process-control activities. While traditional quality measures focus primarily on observed defects, defectives, process capability, and immediate conformance, latent quality risk considers failures or degradation that may emerge later through time, use, exposure, or accumulated process effects. The framework introduces Latent Quality Survival (LQS) and Latent Quality Risk (LQR) and applies survival and reliability concepts to model the probability that quality remains intact as exposure increases. A Weibull-based formulation enables the behaviour of latent quality risk to be characterised through parameters representing early-life effects, approximately constant risk, and wear-out behaviour. The approach extends conventional quality engineering beyond the point of manufacture or inspection by connecting quality, reliability, survival analysis, process capability, Lean Six Sigma, defect prediction, and Quality 4.0. It provides a foundation for identifying, modelling, and managing quality risks that may not be immediately observable at the time of production or inspection. Author: Dr John M. HigginsAffiliation: Six Sigma Training & Consulting (Pty) Ltd, South Africa