The intent of specifically adding an exercise like this to to help highlight the need for an internal non-production department close inspection of the parts being produced. I am not talking about 100x inspection, really just 10X or slightly higher. The goal is to find obvious defects. The inspector should not be targeted toward specific "high risk" areas. I find that the high risk areas, or areas that the inspector would be told to look at, will already be in good control. The concern is the "unknowns". Have the inspector slowly scan around the part looking for "issues". The issues can be anything unusual. I know that this all sounds vague, but there can be some good learnings from this type of exercise.
In some cases, if you have a good magnifier with a display screen a small team can participate in the review. Treat it like a brainstorming session. Things like "discoloration" can be noted, for example. In a real world example, the discoloration was due to feed and speed on a drill. The discoloration was caused by heat and the heat caused micro cracks. the micro cracks probably could have also been identified in this inspection. But noting the discoloration could have driven the machining team to identify the cause and the fix. The damage would have also been more likely to have been identified at that time.
Picture of "Overlapping semi-circular markings and a wrinkled surface texture adjacent to the fracture surface were indicative of cold flow"
Remember, the focus is on the finding the unknowns before your customer does.
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