This occurs when automated vision systems or quality inspectors are calibrated too tightly, flagging minor cosmetic variations as functional defects. It artificially inflates scrap rates and wastes good material. Engineers must adjust the tolerances to balance catching actual flaws without throwing away sellable product.
Heard on the job
The new vision system is causing massive overkill, it's rejecting every housing with a tiny scratch on the back plate.
Also heard as
- false reject
- type I error
Do not mix it up with
- Underkill: Overkill means rejecting good parts, whereas underkill means accidentally passing defective parts.