Quality Checks and Rejections in Production

Checks happen where the work happens, at the stage and at final inspection. Rejection and rework are counted with the reason that caused them.

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Where checks are recorded

Incoming material

Grade, dimension, weight or ingredient checks on a supplier receipt, with a lot held back when it does not read right.

In-process at a stage

A first-piece check or a sample from the running batch, entered on the job card of that stage by the person who measured it.

Final inspection

The whole batch is checked before packing, and the accepted quantity is what goes into finished goods.

Customer complaint

A piece returned by a buyer is logged against the batch and the work order it came from, so the stage behind it can be found.

Readings and check lists

What gets measured differs by trade. A machine shop records diameters and lengths against drawing limits. A fabrication unit notes weld checks and coating thickness, and a food unit records weight, temperature or a taste panel result. The check list for each part is entered once and then appears on the card. A reading outside the limit is flagged as it is typed, which is the point at which a supervisor can still act.

Rejection, rework and hold

Reason codes

Oversize, undersize, porosity, weld crack, paint run, short weight, wrong label and the rest are picked from a list your supervisors agree on.

Rework route

A piece sent back goes to a named stage, and it rejoins the batch count only when that stage passes it again.

Scrap and its weight

Rejected pieces can be weighed as scrap. The scrap figure then stands beside material issued.

Batch hold

A batch under question is held, which keeps it out of packing and dispatch until a named person clears it.

What the client decides

The reason list and which reasons count as rework rather than scrap
Which stages need a first-piece check before running
Who may release a held batch
Whether readings are typed or only a pass mark is kept

FAQ

Frequently asked questions

Can we keep drawing limits on each check?

Yes. Upper and lower limits sit on the check line, and a reading outside them is marked when it is entered.

Are rejections shown by operator?

Yes, because the job card already names who ran the stage. How that view is used is for the owner to settle.

Does it produce an inspection report for a buyer?

Readings saved against a batch can be printed for the buyer. The format a particular buyer insists on is confirmed during scoping.

What happens to a batch that fails after packing?

It is brought back from finished goods with a reason, and the quantity available for dispatch drops by that much.

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