Check quality on receipt, in process and at the end

A check is one inspection of one lot. It can happen when goods arrive, between steps of a run, or on the finished goods. Production → Quality control holds them all, with the Inspections and Non-conformances tabs.

Quality control is a module that has to be on for the workspace.

Where checks come from

• On receipt. A delivery opens an Incoming check when its material, or its supplier, asks for one. See Check incoming deliveries.
• From a step. A work step marked Needs a quality check opens a check when it is finished on a production order. It never blocks the work.
• By hand. Click Record check, choose the Stage (Incoming, In process or Final), the Item, the Lot quantity and the Location, and say what it was Inspected against. One run can carry as many checks as it needs.

Choose a Sampling plan: Every unit, or Sample, with a Sample size and Accept up to a number of defects. You can state it once on the step instead: a share of the batch by how big the batch is, rounded up, so a run of twenty is inspected as seriously as a run of three hundred.

Record the result

Open the check and click Record result.

1. Enter how many units were Accepted and how many Rejected. Together they cannot exceed the lot.
2. If any were rejected, choose the Disposition: Rework, Scrap, Use as is or Return to supplier. With none rejected, the disposition is Accept.
3. For defects found, click Add defect, choose a class (Critical, Major or Minor), the quantity and what was wrong.
4. For Scrap, choose the Spoilage class: Routine (absorbed by the units that survived) or Abnormal (a loss, never in product cost). A supplier’s defect stays a loss.
5. Click Record result.

The result follows from the numbers: Pass with nothing rejected, Pass with concession when rejected units are used as they are, Fail otherwise. A failed check raises a non-conformance on its own.

What happens to the stock

The disposition decides the Stock effect, so a rejected unit is never counted twice:

• Accept and Rework: nothing moves. The redo is consumed by the production run.
• Scrap: on an in-process or final check, one write-off carrying the spoilage class. On an incoming check, nothing moves, because receiving already left those units out of stock. Scrapping a finished product has no stock path yet: record the rejection and raise the finding.
• Use as is: on an incoming check, the units are brought into stock as a concession, at no cost change. In process or final, it is a paper decision and nothing moves.
• Return to supplier: nothing moves here. Raise the return in purchasing. See Decide what happens to defective deliveries.

Closing a check with scrap needs permission to edit both quality and inventory, because writing stock off is a stock write whoever decides it. If a stock effect did not post, the check says Not posted and offers Post stock effect.

Follow a non-conformance

The Non-conformances tab lists findings with their Severity and Status: Open, Contained or Closed. Add the Root cause and Corrective action. A finding outlives the order it was raised on, and closing it requires a corrective action.

Measure a number, not only count defects

On a work step, Measured limits adds what is measured, its unit, a Min and a Max, and how often it repeats (Every, h). A reading is judged against the limits as they stood when it was taken: Within limits, Below minimum or Above maximum. Turn on A reading in limits ends this step and a reading inside the limits closes the check and ends the step. Nothing is scheduled and nothing is sent: the next due time is shown on the check, marked Overdue when it passes.

Related

• Check incoming deliveries
• Cost the work with positions, works and rates