Quality Control
Quality Control (QC) records inspections of goods — from work-order output, purchase receipts, or ad-hoc checks — and routes every unit to one of three fates: good stock, quarantine, or rework. Nothing is lost between the shop floor and the ledger: the passed, failed and rework quantities must reconcile exactly to what was inspected.
Worked scenario — inspecting the 2,000 drums from WO-2418
When WO-2418 completes, its 2,000 finished drums are routed to QC as a single inspection (batch B-2418). The inspector pulls a sample, runs the checks (wall thickness, leak test, lid seal, print legibility), and records the disposition:
| Result | Qty | Where it goes |
|---|---|---|
| Passed | 1,976 | Released to available finished-goods stock |
| Rework | 16 | Flash on the trim line → Rework work order |
| Failed | 8 | Short-shots / warping → Quarantine sub-location |
| Inspected | 2,000 | (1,976 + 16 + 8 must equal this) |
First-pass yield = 1,976 ÷ 2,000 = 98.8%.
Create an inspection
Go to Operations → Quality Control → ＋ New Inspection and complete:
| Field | Notes | This scenario |
|---|---|---|
| Source | Work Order, Goods Receipt, or Ad-hoc. | Work Order WO-2418 |
| Item + Batch | The batch being inspected, if batch-tracked. | 50 L HDPE Drum, batch B-2418 |
| Inspected Qty | Total units checked (or sampled and extrapolated). | 2,000 |
| Passed Qty | Good units — released to available stock. | 1,976 |
| Failed Qty | Defective units — moved to a Quarantine sub-location. | 8 |
| Rework Qty | Units sent back to a Rework work order. | 16 |
| Inspection Date / Inspector | Who checked, and when. | — |
| Notes / photos | Evidence for the record. | Short-shot photos attached |
:::caution The three quantities must sum to inspected
Raya blocks the inspection until Passed + Failed + Rework = Inspected Qty. For
batch B-2418, 1,976 + 8 + 16 = 2,000. If they don't add up, units have gone
unaccounted for between the shop floor and the ledger — reconcile before saving.
:::
Pass, fail, rework — what each disposition does
- Pass — quantity becomes available finished (or received) stock. The 1,976 drums are now sellable and can be packed.
- Fail — quantity is moved to a Quarantine sub-location so it can't be sold or consumed while its fate is decided (scrap, return to vendor, or re-inspect). The 8 short-shot drums sit in Quarantine until dispositioned; scrapping them posts an Adjustment Decrease.
- Rework — quantity feeds a Rework work order to be corrected and re-inspected. The 16 flashed drums go back to the trim station, then return to QC.
Yield after rework
Rework recovers most of the held units. Re-inspecting the 16:
| Stage | Good | Scrapped |
|---|---|---|
| First pass | 1,976 | — |
| Rework re-inspection (16) | 15 | 1 |
| Quarantine disposition (8) | 0 | 8 |
| Batch total | 1,991 good | 9 scrapped |
First-pass yield 98.8%, rising to 99.55% (1,991 ÷ 2,000) after rework. The 9-unit shortfall against the 2,000 ordered is covered from the 1.2% scrap-allowance overrun the moulders ran on WO-2418, so SO-1290 still ships complete.
:::tip Track first-pass yield as a KPI First-pass yield (passed ÷ inspected, before rework) is the honest quality number — 98.8% here. A batch that only reaches target after heavy rework is telling you the moulding process, not QC, needs attention. :::
Non-conformance
A failed inspection raises a non-conformance record against the batch, capturing the defect type, quantity and evidence. Under Advanced Manufacturing a non-conformance can hold the linked work order — blocking its completion until the issue is resolved — which is what you want when a whole batch is suspect rather than a stray 8 units. Here the 8 failures are within tolerance, so WO-2418 is allowed to complete while the 8 drums sit in Quarantine.
:::tip Print for the auditor Every completed inspection can be exported as a result PDF — batch, quantities, yield, inspector and photos — handy for customer quality packs or compliance audits. :::
:::note QC is an independent step QC also serves goods receipts (inspect a purchased component before it enters stock) and ad-hoc checks, so an inspection can exist even when no work order is involved. Subcontracted goods returning from a job-worker are a good candidate to route through QC before they hit available stock. :::
Related
- Work Orders, BOM & Routing — the usual source of QC inspections.
- Packaging — where passed drums go next.
- Subcontracting — inspect vendor-processed goods on return (Advanced).
- Inventory — quarantine sub-locations and batch status.